B, C, D SERIES SERVICE MANUAL

Table of Contents – Page 1 of 1

FOREWORD

SECTION 1: SPECIFICATIONS
TRACTOR SPECIFICATIONS:
TUNE-UP/GENERAL MAINTENANCE SPECIFICATIONS:
TORQUE VALUES:
SPECIAL INSTRUCTIONS
VEHICLE IDENTIFICATION NUMBER (VIN) EXPLANATION

SECTION 2: PRE-DELIVERY SERVICE

B-SERIES, C-SERIES, AND D-SERIES AUTOMATIC TRACTORS

SECTION 3: GENERAL MAINTENANCE

MAINTENANCE CHECKLIST
ENGINE OIL
BATTERY CHECK
TUNE UP PROCEDURE

SECTION 4: ENGINE
CHOKE AND THROTTLE CONTROL ROUTING AND ADJUSTMENT
D-SERIES

SECTION 5: CLUTCH, BRAKES, TRANSMISSION/TRANSAXLE

B-SERIES
C-SERIES
D-SERIES

SECTION 6: ELECTRICAL SYSTEM

B-SERIES
C-SERIES
D-SERIES

SECTION 7: ATTACHMENT LIFTS

B-SERIES
C-SERIES
D-SERIES, AUTOMATIC

SECTION 8: CHASSIS
B AND C-SERIES
D-SERIES

SECTION 9: POWER TAKE-OFF (PTO)

B-SERIES
D-SERIES
 Service Manual

I I

PART NO. 810063Rl

PRICE: $5.00 PRINTED IN U.S.A. 0778
 FOREWORD

ThispublicationhasbeenpreparedtoassistWheelHorsedealersin
servicingBandC-Series, D-160 and D-200 tractors.Informationforthe
C-161 Twin8-SpeedorAutomatic,isgivenseparately a t theendofeach
chapter.

Informationcontainedinthismanualisconcentratedon areas that

require adjustment, as well as removal, replacement, and overhaul of some
of the more complex systems of the tractors. Repair of major assemblies, such
as mechanical and automatic transmissions, and the Onan engine, is detailed
in otherWheelHorseServiceManuals. Repair ofBriggsandStratton or
Kohler engines, and the Peerless transaxle, is described in literature available
from their respective manufacturers.

Knowledgeofbasicmechanicalandelectricalrepairworkisessential
when using this publication. Always observe common shop safety rules while
performing service work.

Replace all parts that are worn or no longer serviceable. Always replace
expendable parts, such as O-rings, gaskets, and seals.

Section 1 listsspecifications,torquevalues,andspecialinstructions
not listed in the general text. It is advised that you become familiar with this
information before making adjustments or repairs.

THIS MANUAL APPLIES TO THE FOLLOWING VEHICLES:

MODEL VEHICLE IDENTIFICATION NUMBER

B-81
4-Speed 82-08BP01, 92-08BP01
B - 1 11 4-Speed 82-11BPO1, 92-11BPO1
C-81
8-Speed 81-08K801, 91- 0 8 K 8 0 1
C-101 8-Speed 81-10K801, 91-10K801
C-121
8-Speed 81-12K801, 91-12K801
C-121
Automatic 81-12KS01
C-1 41 8-Speed 81-14K801, 91-14K801
C-141
Automatic 81-14KS01
C- 16 1 8-Speed 81-16 K 8 0 1
C-I 61 Automatic 81-16KS01
C - 1 6 1 Twin 8-Speed 81-16B801, 91-16 B 8 0 1
C-1 61 Twin Automatic 81-16BS01, 91-16BS01
D - 1 60 Automatic 81-16 0 S 0 1
D - 2 0 0A u t o m a t i c 81-20KS01, 91-20KS01
 TABLE OF CONTENTS

SECTION 1 -SPECIFICATIONS AND GENERAL INFORMATION

SECTION 2 - PRE-DELIVERY SERVICE

SECTION 3 - GENERAL MAINTENANCE

SECTION 4 - ENGINE

SECTION 5 - CLUTCH, BRAKES, TRANSMISSIONN/TRAANSAXLE

SECTION 6 - ELECTRICAL SYSTEM

SECTION 7 - ATTACHMENT LIFTS

SECTION 8 - CHASSIS

SECTION 9 - POWER TAKE-OFF (PTO)

 SPECIFICATIONS SECTION 1
TRACTOR SPECIFICATIONS:
ENGINE:
TRACTOR ENGINE ENGINE RATED DISPLACEMENT BORE STROKE
IGNITION
MODEL* MODEL
SPEC. NO. H.P.** cu. in./cc in./mm in./mm

B-81 B-191707 1136-01 8 19.44/3 18.56 3/76.2 2.75/69.9 Magneto

B-1 1 1 8-252707 0151-01 11 24.36/399.19 3.438/87.3 2.625/66.7 Magneto
C-8 1 K181S PF30700D 8 18.6/304.8 2.94/74.7 2.75/69.8 Battery
C-101 K241AS PF46766D 10 23.9/391.6 3.25/82.6 2.88/72.9 Battery
c-121 K30 1AS PF47648D 12 29.07/476.4 3.38/85.7 3.25/82.6 Battery
C-141 K32 1AS PF60322D 14 31.27/512.4 3.5/88.9 3.25/82.6 Battery
C-161 K34 1AS PF71246A 16 35.89/588.1 3.75/95.3 3.25/82.6 Battery
C-161 Twin B-401407 0130-01 16 40/655.7 3.438/87.3 2.156/54.8 Magneto
D-160 O-BF MS3268F 16 40.3/660.4 3.1 25/79.4 2.625/66.7 Battery
D-200 K532S 53 1O5A 19.9 53.68/879.7 3.38/85.7 3/76.2 Battery
*Letter
Prefix: B Briggs & Stratton,
Kohler,
K Onan. Basic engine
model
number
shown;
specification and serial numbers
from
engine
1. D. plateare requiredtocompletely identify engine.
**
Enginemanufacturer's rating at 3600 RPM.

TRANSMISSION:
B-Series Models C-Series 8-Speed Models
Type: Mechanical Mechanical
All Gear All Gear
Number of
Forward Speeds: 3 6
Number of
Reverse
Speeds: 1 2
Approximate Ground Speeds
(at full throttle): Gear Speed Gear Range
Low High Range
1st
1.7 mph (2.7 kph) 1st .5 mph ( .8 kph) 2 mph (3.2 kph)
2nd 3.6 mph (5.8 kph) 2nd .8 mph (1.3 kph) 3.2 mph (5.2 kph)
3rd 5.5 mph (8.8 kph) 3rd 1.4 mph (2.2 kph) 5.5 mph (8.8 kph)
Rev.
2.5 mph (4 kph) Rev.
.6 mph ( 1 kph) 2.6 mph (4.2 kph)
Series AutomaticModels D-Series Automatic Models
Type: Hydrostatic Hydrostatic
Number of
Forward Speeds: Infinite
Infinite
Number of
Reverse
Speeds: Infinite
Infinite
Approximate Ground Speeds
(at full throttle): Variable04.3mph
(10 kph) Forward Variable 0-7.5 mph (12 kph) Forward
Variable 0-3.2 mph Variable 0-3.6 mph (5.8 kph) Reverse
(5.2 kph) Reverse

12 Type: Volt D.C., Sizes: Front Rear

Negative Ground
B-81 13 X 5:00-6 18 X 8:50-8
Alternator:
Briggs & Stratton - Dual
Circuit, 12 Volt, 3 Amp. B-111 13 X 6:50-6 18 X 9:50-8
(Charging Circuit)
C-Series 16 X 6:50-8 23 X 8250-12
Onan and Kohler -
12 Volt, 15 Amp. D-Series 18 X 8:50-8 26 X 12:00-12
B-81,
Battery: B-111, C-81 - Pressure:
12 Volt, 24 Amp. Hr.
C-101, C-121, C-141, C-161 - 12 12
12 Amp.
Volt, 32 Hr. kg/cm² .85 .85
D-160, D-200 -
12 Volt, 45 Amp. Hr.
1-1
SECTION 1
TRACTOR SPECIFICATIONS (continued):
PHYSICAL DATA:

I TRACTOR
MODEL

B-8 1
HEIGHT

37 in.
LENGTH

65 in.
WIDTH
WHEEL
BASE
OUTSIDE
TURNING RADIUS

34.5 in. 45.5 in. 80in.

(94 cm) (165 cm) (88 cm) (116 cm) (203 cm)
B-111 37 in. 65 in. 36 in. 45.5 in. 80 in.
(94 cm) (165 cm) (92 cm) (116 cm) (203 cm)
C-8 1 41 in. 65in. 36 in. 45.5 in. 75.75 in.
(104 cm) (165 cm) (92 cm) (116 cm) (192 cm)
C-101 41 in. 65 in. 36 in. 45.5 in. 75.75 in.
(104 cm) (165 cm) (92 cm) (116 cm) (192 cm)
c-121 41 in. 65 in. 36 in. 45.5 in. 75.75 in.
8-Speed (104 cm) (165 cm) (92 cm) (116 cm) (192 cm)
c-121 41 in. 65in. 36 in. 45.5 in. 75.75 in.
Automatic (104 cm) (165 cm) (92 cm) (116 cm) (192 cm)
C-141, C-161 41 in. 65in. 36in. 45.5 in. 75.75 in.
8-Speed (104 cm) (165 cm) (92 cm) (116 cm) (192 cm)
C-161 Twin 41 in. 69 in. 36 in. 45.5 in. 75.75 in.
8-Speed (104 cm) (1 75.3 cm) (92 cm) (116 cm) (192 cm)
C-141, C-161 41 in. 65 in. 36 in. 45.5 in. 75.75 in.
Automatic (104 cm) (165 cm) (92 cm) (116 cm) (192 cm)
C-161 Twin 41 in. 69in. 36 in. 45.5 in. 75.75 in.
Automatic (104 cm) (1 75.3 cm) (92 cm) (116 cm) (192 cm)
D-160 45.5 in. 75.5 in. 45 in. 50 in. 90 in.
(116 cm) (192 cm) (114 cm) (127 cm) (229 cm)
D-200 45.5 in. 75.5 in. 45 in. 50 in. 90 in.
(116 cm) (192 cm) (114 cm) (1 27 cm) (229 cm)

TUNE-UP/GENERAL MAINTENANCE SPECIFICATIONS:

ENGINE:
POINT TIMING IGNITION SPARK SPARK DIRECTION IDLE GOVERNED
TRACTOR
GAP MARK TIMING PLUG PLUG GAP OF ROTATION RPM MAX. RPM
MODEL
in./mm LOCATION (BTDC) TYPE' in./mm (Facing PTO) (No Load) (No Load)

8-8 1 .020/.5 N/A Fixed CJ-8 .030/.76 Counterclockwise 1750 3300

B-111 .020/.5 N/A Fixed CJ-8 .030/.76 Counterclockwise 3300 175
C-8 1 .020/.5 N/A Fixed J-8 .025/.64 Counterclockwise 1900 3500
C-101 .020/.5 N/A Fixed H-10 .025/.64 Counterclockwise 2100 3400
c-121 .020/.5 N/A Fixed H-10 .025/.64 Counterclockwise 2100 3400
C-141 .020/.5 N/A Fixed H-10 .025/.64 Counterclockwise 21 00 3400
C-161 .020/.5 N/A Fixed H-10 .025/.64 Counterclockwise 2100 3400
C-161 Twin .020/.5 N/A Fixed J-8 .030/.8 Counterclockwise 1450 3300
D-160 .023/.6 Flywheel 25" (Cold) H-8 .025/.64 Counterclockwise 3600 1350
D-200 .020/.5 Flywheel 27" H-10 .035/.9 Counterclockwise 1350 3600
'Or equivalent(Championnumbershown).
 SECTION 1

TUNE-UP/GENERAL MAINTENANCE SPECIFICATIONS

(continued):
LIQUID CAPACITIES:

Crankcase:
B-81 1-1/8 qt. (1.1 I)
B-111 1½ qt. (1.4 I)
C-81 1¼ qt.(1.2 I)
C-101 1½ qt. (1.4 I )
c-121 1½ qt. (1.4 I )
C-141 1½ qt. (1.4 I)
C-161 1½ qt. (1.4 I)
C-161 Twin 1¾ qt. (1.7 I)
D-160 2¼ qt. (2.1 I) w/filter
D-200 3½ qt. (3.3 I) w/filter
Transmission :
B-Series ¾ qt. '( .7 I) SAE 90, API Service GL5
C-Series 8-Speed 2 qt. (1.9 I ) SAE 140, API Service GL5
C-Series Automatic 5.5 qt. (5.2 I ) SAE 1 OW-30 or 1 OW-40
D-Series 6 qt. (5.7 I) SAE 10W-30 or 10W-40
Fuel Tank:
B-Series 1½ gal. (5.7 I)
C-Series 3 gal. ( 1 1.4 I)
D-160 5¾ gal. (21.9 I)
D-200 8 gal. (30.4 I)

ENGINE OIL: TEMPERATURE VISCOSITY CHART

Air Temperature Oil Viscosity
Briggs and Stratton Engine
Above 40ºF (4°C) SAE 30*. 10W-30,10W-40
40ºto0°F(4°to -1 8ºC) SAE 5W-20
or 5W-30*, 10W, 10W-30
Below 0°F(-1 8ºC) SAE 1OW or 1OW-30, Diluted 10%with kerosene
APIService: "SC” (MM), "SD" (MS) or "SE" oil

Kohler Engine
Above 30ºF (-1°C) SAE 130*, 0W-30,1 OW-40
30ºto 0°F (-1° to -18°C) SAE 10*. 5W-30. 10W-30. 10W-40
1 Below 0°F (-18°C) 5W-30
5W-20.
SAE
or

i API Service: "SC" (MM), "SD" (MS) or "SE" oil

Onan Engine
Above 30ºF (-1°C) SAE 30
Below 30ºF (-1°C) 5W-30 SAE
APIService: "SE" oil
* Preferred viscosity. Use alternates listed if preferred
viscosity is unavailable.

CHASSIS:

Fittings: PTOBrake Adjustment (PTO engaged): Zerk Front Wheel End Play:
All Models 0 to .015 in. (.4 mm)
B-Series 6 B-Series .010 (.25 mm) Gap D-200 .012 (.3 mm) Gap
C-Series 6 between brake pad and pulley between brake pad and pulley Front Wheel Alignment (toe-in):
D-Series C-Series .012 (.3 mm) Gap D-160 .010/.015 (.25 - .4 mm) D-Series only 1/16 - 1/8 in.
betweenbrake
pad
and pulley Gap
between rotor and armature (1.6 - 3.2 mm)

1-3
SECTION 1

TORQUE VALUES:
SPECIAL
Torque
Tractor Model Location
ft-lb Nm

Rear wheel hub set screws 28 - 32 39 - 45

C-Series Fuel tank front bolt 5-8 7 - 11.2
Fuel tank insert bolt 5-8 7 - 11.2

D-Series Fuel tank nuts 17 12

D-Series Models
GENERAL
Fasten rectifier wire to inside edge of frame with wire

I Size
Torque
ft-lb Nm
clip
Align front wheels for 1/16 to 1/8 inch (1.6 to 3.2 mm)
toe-in
1/4 - 20 8 11 Steering gear to contain 1/4 lb. (0.1 kg) grease
5/16 - 18 17 - 22 24 - 31 Adjust choke and throttle friction to provide 8 to 10 Ib.
3/8 - 16 30 - 35 42 - 49 (1.8 to 2.3N) pull force a t knobs
3/8 - 24 25 - 30 35 - 42 Adjust friction on control cam to provide16 to 20Ib.
171
/ 250--518-301 1 2 (3.6 to 4.5N) pull force at top of motion control lever
Tie wrap wiring harness t o steering column
-
Self Tapping Screws All Models Grease input shaft spline of hydro pump and brake rod
(approximately 2 inches past threaded end) with "moly"
5/16 - 18 grease.
3/8 - 16 25 35 Locate bottom edge of muffler 1 3/4 inch (4.4 cm)
above grille shroud assembly
Adjust brakerods so brakebandjustclears drum with
SPECIAL INSTRUCTIONS pedalreleased
Adjust parkbrake rod with brakehandle in engaged
All Models position
Lube all grease fittings with No. 2 General Purpose Install spring disc washers on choke and throttle controls
lithium grease as shown in Fig. 1-1.
Coat exposed areas of axle hubs with anti-rust lubricant
(TexacoCompound"L," Light, Code 1976 or equivalent)
Install seat spring long leg toward seat.

C-Series Models

Adjust lift chain so length from bolt through lower link

to trunnion center i s 7.4inches (19 cm). For final ad-
justment, see Section 7
Kohler engines:assembleenginePTO pulley 1/16 inch
(1.6 mm) from engine face
Adjust PTO brake to provide .012" ( 3mm) clearance be-
tweenbrakepadand pulley when clutch is engaged
Coat lift lever shaft with anti-rust lubricant (Texaco
Compound"L," Light, Code 1976 or equivalent)
Use lsomount No.106434, color code white, for all
models except
C-81. Use lsomount No. 106441, no
color code, for C-81 models SPRING
DISC
WASHER FRICTION
Fuel hose must remain clear of Sundstrand Transmission. ONE ONWASHER
CHOKE
Securehose to top of transaxleand bottom of hood- TWO
ON THROTTLE (1 00305)
stand.

Fig. 1-1 Control Friction

1-4
 SECTION 1

PTOBrake Adjustment: D-200 cable t i e headlight wire and ignition wire to the
a. D-160 adjust PTO brake for .010/.015 inch (.25 to governor vacuum hose
.4 mm) gapbetween rotor and armature assembly
b. D-200 adjust PTO brake for .012 inch (.3 mm) gap D-200 PTO adjust
PTO clutch hook to 1 13/16
betweenbrakepadand pulley with PTOengaged inch (4.6 cm) from engineface to hook centerline. Ad-
FlexCoupling just clutch turnbuckle for 16 to 18 Ib.(3.6 to 4.0 N).
a. D-160 install engine/pump flex coupling parts as pull on clutch handle,and complete disengagement of
shown in Fig. 1-2 clutch pulley

D-200 greasechromebearingsurface of PTO clutch

106641 SPLINE WASHER plate with "moly" grease.

103029 DRIVEN COUPLING

920008 WASHER (4) REQUIRED

C-I61 TWIN
TORQUE VALUES:
Same as C-Series

SPECIAL INSTRUCTIONS:
Same as C-Series except:
Drivepulley set screw to betightened
while PTO is engaged to pre-load thrust
bearing.

I
920082 LOCKWASHER
908023 BOLT

106645 MOUNTING PLATE

Fig. 1-2 D-160 FlexCoupling

b. D-200 install engine/pump flex coupling parts as

shown in Fig. 1-3

106641 SPLINE WASHER

103029 DRIVEN COUPLING
920008 WASHER (4) REQUIRED

8021 NYLOK BOLT

ENGINE

920082 LOCKWASHER
908023 BOLT
106645 MOUNTING PLATE

Fig. 1-3 D200 FlexCoupling

1-5
 VEHICLE IDENTIFICATION NUMBER (VIN) EXPLANATION SECTION 1

JULIAN DATE
and day manufactured

81-20RG 01-00001 7 365

MODELYEAR SERIAL NUMBER

6 = 1976 00001 through 99999 365th day
7 = 1977 of year
8 = 1978
9 = 1979 PARTS LIST CODE I YEAR 1
0 = 1980 01 through 99 7 = 1977
1 = 1981 8 = 1978
2 = 1982
3 = 1983
4 = 1984

PRODUCTCATEGORY
1 = GARDENTRACTORS
1
ENGINE MAKE CODE TRANSMISSION MAKE CODE
2 = LAWNTRACTORS B = BRIGGS &STRATTON E = EATON
3 = RIDERS K = KOHLER F = FOOTE
4 = SNOWTHROWERS- O = ONAN G = GUTBROD
WALK-BEHIND R = RENAULT P = PEERLESS
5 = ROTARYMOWER T = TECUMSEH S = SUNDSTRAND
ATTACHMENTS E = BATTERY POWER 4 = 4-SPEEDWHEELHORSE
6 = SNOWREMOVAL 8 = 8-SPEEDWHEELHORSE
ATTACHMENTS
7 = TILLAGE ANDYARD PRODUCT CATEGORY5
ATTACHMENTS MS = MID MOUNT,SIDEDISCHARGE
8 = NOTASSIGNED MR = MID MOUNT,REARDISCHARGE
9 = NOT ASSIGNED RS = REARMOUNT,SIDEDISCHARGE
0 = NOT ASSIGNED R R = REARMOUNT,REARDISCHARGE
FS = FRONTMOUNT,SIDEDISCHARGE
EFFECTIVE
CATEGORY
MEASUREMENT I FR = FRONT
MOUNT,
DISCHARGE
REAR
IE - HORSEPOWER, WIDTH OR CAPACITY FOR:
PRODUCT CATEGORY6
ST = SNOW THROWER
PRODUCT
CATEGORIES 1,2,3,4
PRODUCT
42
CATEGORY6
= 42” BA = SNOW BLADE
05 = 5 H.P. BC = SNOW BLADE
48 = 48“ WIDTH
08 = 8 H.P. BN = SNOW BLADE
56 = 56” WIDTH
10 = 10
H.P.
59 = 59” WIDTH
11 = H.P.
11 PRODUCT CATEGORY7
12 = 12H.P. BM = BLADE,MIDMOUNT
14 = 14H.P. PRODUCT CATEGORY7 TE = TILLER(BATTERY)
16 = 16H.P. 08 = 8”
FURROW WIDTH TL = TILLER
20 = 20H.P. 12 = 12”
FURROW WIDTH PL = MOLDBOARD PLOW
05 = CU.
5 FT.CAPACITY PR = PLOW,REVERSIBLE
PRODUCT CATEGORY5 10 = 10CU.FT.CAPACITY DS = DISC
26 = 26”
CUT WIDTH 18 = 18CU.FT.CAPACITY HR = HARROW
30 = 30”
CUTWIDTH 31 = 31”WIDTH PT = PLANTER
32 = 32”CUTWIDTH 38 = 38”
WIDTH CM = CULTIVATOR,MIDMOUNT
36 = 36” CUTWIDTH 40 = 40”
WIDTH CR = CULTIVATOR,REARMOUNT
42 = 42”CUTWIDTH 42 = 42”
WIDTH WG = WAGON,4-WHEEL
48 = 48“
CUTWIDTH 44 = 44”
WIDTH DC = DUMP CART
60 = 60”CUTWIDTH 50 = 50“
WIDTH RL = ROLLER
59 = 59“
WIDTH AR = AERATOR
ETC. SW = SWEEPER
VC = LAWNVACUUM

* IN CERTAINCASES, THIS MAYBE CODED WITHA N “X”, “Y”,OR “Z”IN EITHER POSITION. THIS IS TO A VOID
TION OF V.I.N. NUMBERS WHEREBASIC PRODUCT INFORMATION IS IDENTICAL. EXAMPLE: 85-36MR01 AND 85-36XR01.

1-6
PRE-DELIVERY SERVICE SECTION 2

B-SERIES, C-SERIES, and D-SERIES Automatic Tractors

Install Front Wheel and Tire Assemblies
Using a suitablehoistor jack,raise the frontof the
.015”(Thin) Shim Washer
tractor.
A. If a floor jack is used,center the jack under the frame
assembly behind the front axle. Use a 2” x 4” piece of
lumber or similarmaterial, long enough to span the
width of the frame,between the jackand the tractor
to prevent damage to the vehicle.
B. If a chain hoist is used, attach the hoist to the front
axle, being careful not to scratch the side of the engine,
hood, or the axle itself. On C andD-Series tractors, an
alternate hoisting point can be
made by installing a
piece of rod stock (5/8” on C-Series; 3/4” on D-Series)
in the front Tach-a-matic hitch. Be careful notto
1 O.D. Washer
scratch the grille.
Install a wheeland tire assemblyoneachspindle as
illustrated in Fig.2-1,2-2, or 2-3, as appropriate. The
Fig. 2-3 DSeries Front Wheel Installation
tire valve stem should be to the outside on B-Series vehicles
and to theinsideon C andD-Seriesvehicles. Correct Install Footrest (D-Series Only)
wheel end play is 0 to .015 inch (.4 mm). In some cases it
may be necessary to addorremove a shimwasher to Raise the rear of the tractor (see Install Rear Wheel and
achieve correct end play. Tire Assemblies). Install the footrests as shown in Fig. 2-4.
Note that the bolt holding the rear of the mid lift bearing
must be removed to install the footrest and is replaced after
the footrest is installed.The ”L” shaped bracket is in-
D. Washer stalled a t the front of each footrest as shown in Fig. 2-4.

.015” (Thin) Shim Washer

.050”(Thick)ShimWasher
Snap Ring
Hub Cap
1 D. Washer

Fig. 2-1 B-Series Front Wheel Installation

.015”(Thin) Shim Washer

.050” (Thick) Shim Washer

11 O.D. Washer Fig. 2-4 DSeries Footrest Installation

Install Rear Wheel and Tire Assemblies

Raise the rear of the tractor.
A. If a floor jack is used,center the jack under the trans-
mission case. Use a 2“ x 4” block of wood or similar
Fig. 2-2 C-Series Front Wheel Installation material, between the jack and the transmission to pre-
vent damage to the transmission case.
2-1
SECTION 2
B. If a chain hoist is used, attach the hoist to the drawbar
hitch on C and D-Series tractors and to the rear axle on
B-Series tractors.
B-SERIES
Apply a coating of rust preventative on the axle shafts
(Texaco Compound "L," Light, Code 1976, or equivalent).
Mount a rear wheel and tire on each axle shaft as shown in
Fig.2-5, with the tire valve stem to theoutside. Use the
shim washers as required for minimum end play. Lower the
tractor, and remove the jack or hoist.
.015" (Thin)
.OBO"(Thick)
Shim Washers (As Req.'d)
D-SERIES
With the front wheels straight ahead,place the steering
wheel on the steering shaft so that the spokes form a "Y".
Secure the wheel with a 5/8-18 jam nut. Snap the steering
wheel insert into place so the "R", inside the wheel, is
straight when viewed from the driver's seat.
Service the Battery
CAUTION
Electrolyte and battery fluid arepoisonousandcan
be injurious to eyes,skin,and clothing. In the event
of an accident, flush immediately with a solution of
one part baking soda to four partswater. Notify
physician immediately. If baking soda is not imme-
diately available, flush affected area with water. Noti-
fy physician immediately.

Remove
1. the battery from the tractor. Never fill
battery with electrolyte with battery installed in tractor.
2. Usean electrolyte with a specific gravity of 1.260; fill
each cell until the electrolyte (battery acid) i s 1/4 to 1/2
inch (6 to 13 mm) over the top of the separators.DO
NOT OVERFILL.
3. Place the filled dry charged battery on charge before in-
stalling. Charge a t 15 amperes for 30 minutes. After
charging, top off each cell with electrolyte.

Fig. 2-5 B-SeriesRearWheel Installation

C AND D-SERIES After battery has

been in service,
add onlylow
Mount a rear wheel and tire assembly on each axle hub mineral content water.DO NOT ADD ELECTRO-
so the tire valve stem faces inside on the C-Series and out- LYTE (battery acid).
side on the D-Series.Secureeachwheeland tire assembly
with the lug bolts provided. OnC-Series tractors, starting
a t the top, tighten every other lug bolt until all are tight.
OnD-Series tractors, alternately tighten lug bolts on
opposite sides of thewheel until all are tight. Torque the
lug bolts to 75 to 80 ft. Ibs. (105 to 112 Nm).
Lower the tractor and remove the
jack or hoist.

Adjust Tire Pressure

Using a low pressure tire gauge, adjust the tire pressure
in all four tires:

Front Rear
PSI 12 12
kg/cm²
.85 .85

Mount Steering Wheel

a
B A N D C-SERIES
Install the bowed spring washerand plastic spacerover
REAR,C-SERIES
thesteeringshaft. With the wheels straight ahead, install
steering wheel so that the spokes form a "Y" and line up FRONT, B-SERIES
thehole in the wheel hub with thehole in thesteering
shaft.
Insert a 1/4 punch through the hole to hold the steering
wheel in position. Install the 1/4 2 x spirol pin by
driving it in with a hammer; as the spirol pin is driven in, it
should push the punch out. Fig. 2-6 B and C-Series Battery Installation
2-2
 SECTION 21
4. Install battery in the tractor, making sure the terminal of seat pivot plate on D-Series tractors. Remove the hard-
posts
are positioned properly. Install the battery wareand re-attach seat springs to top side of seat pivot
hold down assembly. Tighten thenuts only enough plate. See Fig. 2-8.
to keep the battery from moving.DO NOT OVER-
TIGHTEN.
5. Reinstall the battery cables as shown in Fig. 2-6 and
Fig. 2-7. Grease all exposedmetalsurfaces of the
battery terminals.

Fig. 2-8 DSeries Seat Installation

Check Wiring and Attaching Hardware

Visually inspect for any loose connections and tight-
en as required. Check routing of wires to makesure
Fig. 2-7 D-Series Battery Installation they willnot be disturbedby any moving part that
could cause a short.
Check Engine Oil Level Check that nuts,bolts,and other fastenersare in
placeand tight.
Check that the engine oil is a t theproper level and
for oil leaks.Enginesare filled with SAE 30 oil a t the Fill the Fuel Tank
factory. If the tractor is to be operated in cold tempera-
Use a good grade of regular or unleaded gasoline (90
tures, it may be necessary to change the oil. Refer to the
octaneorhigher).Open the fuel shut-off valve and
Engine Oil Temperature-ViscosityChart in Section 1.
check fuel hose and fittings for leaks.

Check Transmission Oil Level Lubricate Tractor

Check that the transmission oil is a t the proper level
and for oil leaks. Oil specifications are:
4-Speed Transmission SAE 90
8-Speed Transmission SAE 140
Automatic Transmission SAE 10W-30 to 1 0W-40
Install Seat (C and D-Series Only)
Mount seat to seat springs with lockwashersand bolts on
C-Series models. The seat springs are secured to the bottom
2-3
Grease all lube points as shown in themaintenance
section of the tractor Owner's Manual (front axle, both
front wheelspindles, both front wheels,andsteering
gear;onD-Series tractors, also grease thesteering gear
bel crank). Use No. 2 multi-purpose lithium grease.
Test Tractor Operation
A. As applicable, checkor test operation of the following:
1. Engine, choke, and throttle controls
2. Gauges
SECTION 2

3. Lights
4. PTO clutch and brake Check Front Wheel Alignment (D-Series Only)
5. Lift system With the tractor's wheels straight ahead, there should
6. Service and parking brakes
be a small amount (1/16 to 1/8 inch/1.5 to 3 mm) of
7. Transmission clutch "toe-in" adjustment.
8. Transmission controls
If required, adjust the steering as described in Section
9. Steering
8.
10. Tractor operation in all speeds forward and reverse
B. Test operation of thesafety interlock system.The Install Drawbar Hitch Pin (C and D-Series Only)
engine should NOT start if:
1. a) The clutch pedal is not depressed on manual Install thedrawbar hitch pin in thedrawbar hitch
transmissionmodels.
and secure with a hairpin cotter.
b) The brake/return to neutral pedal is not de-
pressed on automatic transmission models.
2. ThePTOleveror switch is in the EngagedorOn Install Mower Belt Adjustment Bolt (B-Series Only)
position.
Threadthe 3/8-16 nut onto the 3/8-16 x 2 full
.On models so equipped, also check the operation of
the seat switch. With the engine running and the PTO thread bolt; threadthe bolt into the front side of the
engaged, rise off the tractor's seat the engine should mower hanger bracket, located just behindthe front axle.
shut off. Tighten the nut against the bracket to secure.
C. On automatic transmissionmodels,check that the
transmission neutral adjustment is properly set. Oper-
ate the tractor under fullthrottle and allow it to
thoroughly warmup. Bring the tractor to a stop
usingthe brake/return to neutral pedal. Release the Follow procedure for C-Series.
pedal; if the tractor "creeps" in either direction, set
theneutraladjustment as described in Section 5.

NOTES
GENERAL MAINTENANCE SECTION
3

MAINTENANCE CHECKLIST ENGINE OIL

Oil Level

Never overfill the enginecrankcase with oil. The oil

level must not exceed the "F" level on the dipstick.

&SERIES
The oil level should be to the top of the oil fill tube.
Check:
Engine Oil Level X
Battery Water Level X
Transmission Automatic X
Oil Level Manual X
Tire Pressures X
Tightness of all
Attaching Hardware X
Clean Engine Cooling Fins
Clean Air Filter
B-Series X
C & D-Series X
Lubricate Chassis X
Change Engine Oil X
Fig. 3-1 &Series Oil Fill and Drain Plugs
Replace Engine Oil
Filter X
Inspect Spark Plugs X C-SERIES
Replace Spark Plug(s) Onengines with oil filler tubes,remove the dip-
I I
stick by twisting the cap slightly and pulling. Engines
Inspect Breaker Points 100 Hours without oil filler tubes have a combination filler plug
Replace Air Filter 100 Hours/One and dipstick located on the right side of the engine
Change Transmission Oil block.
(Automatic) 100 Hours/One
Replace Transmission Oil
Filter
(Automatic) 100 Hours/One
ReplaceFuel Filter (D-Series) 100 Hours/One
Clean and Lubricate
PTO Clutch (D-200) 100 Hours/One

( 1 ) Refertotextforinitial service intervalfornew tractors.

(2) Whichever occurs first.

I
These
service intervals areconsidered MAXIMUM
under
normaloperating
conditions.
Increase
fre-
quencyunder extremely dirty ordustyconditions.
I I
Fig. 3-2 C-Series Filler Plug Dipstick
.SECTION 3

D-SERIES Be sure to add the same viscosity oil as is presently in the

Remove theD-160dipstickby twisting the cap engine.New tractors areshipped with SAE 30 oil in the
slightlyandpulling.TheD-200dipstick is removed crankcase. It maybenecessary to change theoriginal oil
by turning the cap counterclockwiseand then pulling. beforeusingthetractor i f the tractor will be operated in
cold weather.

Oil Changes

Failure to change the engine oil (and oil filter on D-

Seriesmodels) a t recommended intervals can lead to
seriousdamage to the engine. This is especially true
when using detergent oils which are designed to hold
impurities in suspension;when the saturation point
is reached, the oil may suddenly break down to form
a gelatin-like substance which'seriouslyimpairsand
caneven stopthe flowof oil. Increase the fre-
quency of oil and oil filter changes if the tractor is
operated under extremely dusty conditions.
OIL DRAIN
PLUG
Before changing the oil, start the engine and allow it to
warm up. This will allow the oil to flow more freely. Shut
Fig. 3-3 D-160 Oil Dipstick and Drain Plug off the engine and remove the key.
After adding the prescribed amount of oil, check the oil
level. Add oil as necessary to bringthe oil to the "Full"
level in B-Seriesengines or into the "Safe"range onthe
dipstick in C and D-Series engines.

NEVER overfill theenginecrankcase with oil. The

oil level must not exceed the "F" level onthe dip-

Oil Filter (D-160, D-200)

Fig. 3-4 Oil Dipstick and Drain Plug
The engine in D-160 and D-200 tractors is equipped with
a full flow oil filter. The filter should be replacedalong
with the engine oil afterthe first2 hours of operation.
Thereafter,the filter should be replaced a t 50 operating
hourintervals(everysecond oil change),orsooner if the
tractor is operated under extremely dusty conditions.

Fig. 3-5 Correct Oil Level - C and D-Series Fig. 3-6 Right Side Engine Baffle Removed, D-200
 SECTION

To preventany dirt orothercontaminants from

entering the engine,alwayscover the carburetor air
horn when the air cleaner is removed.

B-SERIES
To service the air filter, remove the two screws
lift off the complete air cleanerassembly.Remove the
screenandspacers from thefoamelementand remove
the element from the body of the air cleaner.

Fig. 3-7 Engine Oil Filter, D-160

Fig. 3-9 B-Series Air Cleaners

Wash the foam element in a solution of liquid

gentandwater.Wrap the foam in a clean cloth and
squeeze dry. Saturatetheelement in cleanengine
(same viscosity as is presently being used in the engine
and squeeze to remove excess oil.
Fig. 3-8 Remove Oil Filter, D-Series Whenassembling,make certainthe lip of the foam
elementextendsovertheedge of the air cleaner body

Hand tighten oilfilter only; turn filteruntil the C-SERIES AND D-200
rubber gasket contacts
the engine block, The dry type air filter element installed on C-Series
then tighten an additional 1/4 to 1/2 turn. Excessive and D-200 engines is cleaned by tapping it lightly on
tightening or use of a wrenchorothermechanical flat surface to removeloose dirt particles.Replacethe
devicecancausedamage to both the filter and the element if dirt does not drop off easily. DO NOT was;
engine. elements in any liquid or attempt to blow dirt off with
compressed air as this will puncture the filter elemen..

Air Filter
Clean the engine air filter on B-Series tractors after
every 25 hours of operation, and after every 50 hours of
operation on C andD-Series tractors (more often if the
tractor is operatedunderextremelydusty conditions).
Replace dry type filter elements a t 100 hour intervals,
or once a year,whichevercomes first. The foam type ele-
ments used on B-Series vehicles may be serviceableformore
than 100 hours or one year of operation, provided the ele-
ment shows no sign of deterioration and can still be cleaned
satisfactorily, Replacement intervals must be
shortened
when operating under extremely dusty conditions. To pro-
tect the engine,use only themanufacturer'sreplacement
filter, or replacement filters with equivalent specifications.
Fig. 3-10 C-Series and D-200 Air Cleaner

3-3
SECTION 3

Check the following when installing a new or serviced

element:
1. Back plate mustbesecurely tightened to carburetor.
Replace back plate if bent or cracked.
2.Gasketsurfaces of element must be flat against back
plate cover to seal effectively.
3. Wing nut must be finger tight DO NOT OVER-
TIGHTEN.

The D-200 andsomeC-Seriesenginesare equipped

with a precleaner slipped over the dry element,which FULLY C H A R G E D GOI N G D O W N
traps much of the dirt and prevents it from entering the Acid in water gives electrolyte As battery discharges, acid
dry element.Servicing of theprecleaner is accomplish- specific gravity of 1.260. begins to lodge in plates.
ed by washing it in soap and water, rinsing, then squeez- Specific gravity drops.
ing out the excesswaterand allowing it to dry. DO
NOT OIL THE PRECLEANER.

D-160
Adry type element with precleaner is used onthe
D-160's engine. Cleaning of the filter element, plus the
checks to makewhen installing a new or serviced ele-
ment,are the same as described in this sectionunder
"C-Series
andD-200."Theprecleaner is serviced as
described in the following paragraph. END/LIFE DISCHARGED
To clean the precleaner, wash in water and detergent, Battery half discharged. Acid almost entirely in
removeexcesswater by squeezing like a spongeand More acid in plates, less in plates, leaving weak electro-
allow to thoroughly dry. Distribute threetablespoons electrolyte. Starting lyte behind. Specific gravity
lower, almost that of water.
of SAE 30 engine oil evenlyaroundtheprecleaner. failure likely.

Fig. 3-12 Battery Chemistry

In reading a hydrometer, the barrel must be held verti-

cally. Drawjust enoughacid into thebarrel to lift the
float. The float should not touch any part of the barrel.

I
Fig. 3-11 D-160 Air Cleaner

BATTERY CHECK
A hydrometer is used to measure specific gravity of the
battery. The water level in the battery should be a t normal
height when a hydrometerreading is taken.Hydrometer
readings should never be taken immediately after water has
beenadded.Thewater should be thoroughly mixed with High
float (left) means high Correctmethodof
specific gravity.
Low
float reading hydrometer.
the electrolyte, by charging, before hydrometer valuesare means low specific gravity. Eyeon level with
liquidsurface. Dis-
reliable. regard
curvature
of liquid against
glass parts. Do not
t i It hydrometer
while reading.
Keep float vertical.

Fig. 3-13 Reading Hydrometer

3-4
 SECTION

Fig. 3-14 D-160 Fuel Filter Thebreaker points on Briggs & Stratton enginesare
located under the flywheel. Refer to Briggs & Stratton
ServiceandRepair Instructions (Briggs & Stratton Part
Number 270962) for correct flywheel removal p r o
cedures.

HERE
SCREW TO
DRIVER
MOVE
CONDENSER
BACKWARD \

KEYWAY IN CRANKSHAFT

SCREW DRIVER
HERETOMOVE

Fig. 3-15 D-200 Fuel Filter

TUNE UP PROCEDURE
Spark Plugs
Replacesparkplugs that are not in good condition. Fig. 3-17 &Series Breaker Points
Neversandblast, wire brush,scrape,or otherwise service
sparkplugs in poor condition. Bestresultsare obtained
with new plugs. C-SERIES & D-200
Alwayscheckthespark plug gapbefore installing new 1. Remove the breaker point cover.
plug(s) or reinstalling the original plug(s). Use a spark plug 2. Turn the engineover until the breaker points are!
gap gauge to adjust the electrode air gap. fully opened.
3. Check the condition of the point surfaces.Always;
replace burned or pitted points. Dirty or oily points;
Tractor Model Plug Gap canbecleaned with a cloth, but makesure no par-
B-Series .030in. (.8 mm) ticles of lint remain between point surfaces.
C-Series & D-160 .025 in. (.6 mm) 4. Measure the gap with a feelergauge.When the points;
D-200 .035 in. (.9 mm) are fully open, the gap should be .020 inch (.5 mm)..
Adjust points as necessary.
Tighten spark plug(s) to 22 ft. Ibs. (30 Nm).

3-5
SECTION 3
6. Remove theair intake hose that connects to the
blower housing.Thisprovidesan access to viewing
the timing mark.

I I
Fig. 3-18 C-Series Breaker Points

Fig. 3-20 D-160Breaker Point Gap

7. Check the ignition timing by connecting a continuity

light across the ignition breaker points. Connect one
lead from the light to the negative side of the ignition
coil (terminal that leads into thebreaker box to the
breaker points). Ground the other lead of the light to
a good ground on the engine.
8. Turn the engine crankshaft counterclockwise until
the points close. The light should now be on.
9. Slowly turn the crankshaftclockwise. Adjust the
point gap so the lamp goes out as the timing mark on
Fig. 3-19 D-200 Breaker Point Adjustment the flywheel aligns with the 25° BTC(before top
center) mark.
Under normal operating conditions, a certain amount
of buildup or metal transfer between the point surfaces
will occur. If this occurs too frequently andbecomes
excessive, the condenser may be a t fault.

Dl 60
The points are located on the top of the front side of
the engine inside a breaker box.
To check the breaker points, with a cold engine,re-
move the two nuts holding the heat baffle t o the top of
the engine and remove the heat baffle. Use the following
procedure to check and
adjust
breaker points gap.
TIMING MARKS THROUGH

1. Removethe two screwsand the breakerbox cap.

2. Remove the two sparkplugs so theenginecanbe CORRECT TIMING 25°
turned by hand.Check the condition of the spark BTC COLD SETTING
plugs a t this time.
3. Turn theengineover until the breaker points are
fully opened.
4. Check the condition of the breaker point surfaces. Fig. 3-21 D-160 Timing Mark
Always replace burned, or pitted points. Dirty or oily
points can be cleaned with a cloth, but make sure no
particles oflint remain
between point surfaces. Under normal operating conditions, a certain amount
5. If point replacement is necessary, replace the breaker or buildup or metal transfer between the point surfaces
points with a new set. Adjust point gap to an initial will occur. I f this occurs too frequently andbecomes
setting of .023 inch (.6mm). excessive, the condenser may be a t fault.
3-6
 SECTION 3
Timing
B-SERIES,C-SERIES, AND D-160

Ignition timing on the B, C, and D-160 models is con-

trolled by the point gapsetting.Refer to Pointsand
Condenser.

D-200
The ignition timing should be checked each time the
breaker point gap is altered.
To check the ignition timing connect an automotive
type timinglight to thehightension lead of the left
sparkplug. Consultthemanufacturer's instructionfor
exact connections of the particular type of timing light
used.
Rotate the engine until the "SP" mark is observed in
the timing sight hole; using a piece of chalk, mark the
line for easier reading.
Fig. 3-23 Governor Flange Mounting Screws

Carburetor Adjustment
Carburetorsareadjusted in the factory and should not
have to be reset. I f however,one of the following con-
ditions is noted,the carburetor should be readjusted im-
mediately as continued operation with incorrect setting can
lead to fouled sparkplugs,overheating, excessivevalve
wear,or other problems. If black exhaust smoke is noted,
check the air cleaner first - an "overrich" mixture is usu-
ally caused by a poorly serviced, clogged air cleaner element,
not an improperly adjusted carburetor.

CONDITION
A. Black, sooty exhaust smoke, engine sluggish.
B. Engine misses and backfires a t high speed.
C. Engine starts, sputters, and dies under cold weather
Fig. 3-22 Timing the D-200 starting.
D. Engine runs rough or stalls a t idle speed.
Startthe engineand run a t 1/2 throttle orabove.
Aim the timing light into the sight hole; the light should
flashjust as the "SP" mark is centered in the hole. I f POSSIBLE CAUSE/PROBABLE REMEDY
the light flashes before the mark is centered, the timing A. Mixture too rich - readjust main fuel needle.
is excessivelyadvanced. If the light flashes afterthe B. Mixture too lean - readjust main fuel needle.
mark is centered, the timing is excessivelyretarded. C. Idle speed too low or improper idle adjustment -
To
adjust,
loosen
(DO NOT REMOVE) governor readjust speed, then idle fuel needle if needed.
flange mounting capscrews and rotate the governor until
the timing mark is centeredexactly in the sight hole.
Retighten flange mounting screws after exact timing is
achieved.
 SECTION 3

If readjustment becomes necessary, stopthe engine,

MAIN FUEL
then turn the MAIN and IDLE fueladjusting screws all the LOW S P E E D S E T (HIGH SPEED)
ON GOVERNOR
way in until they bottom LIGHTLY - don't forcethem LINKAGE- SMALL
ADJUSTMENT
closed, as this will damage the needle valves. GAP HERE AT NO
For preliminary settings, refer to the chart below.

INITIAL CARBURETOR ADJUSTMENT CHART

Main
THROTTLE IDLE
turns turns
Valveturns turns STOP ADJUSTMENT
SCREW
Idle Valve SIDE VIEW REAR VIEW
turns turns turns turns

For final adjustments, start engine and allow it to warm Fig. 3-26 D-160 Carburetor Adjustment
up, then operate a t full throttle. Turn MAIN fuel in until
engine slows down (lean side), then out until it slows down
again from overrich setting - note positions of screw a t I D L E FUEL
ADJUSTMENT
both settings, then set it about halfway between the two. ( 1 1/4 TURNS OPEN)
The IDLE fuel setting can then beadjusted in the same
manner for smoothest idle. Rough idle is often due to the
idle speed being set too low - check this also.

I
VALVE IDLE

Fig. 3-27 D-200 Carburetor Adjustment

NEEDLEVALVE

Fig. 3-24 B-Series Carburetor Adjustment

IDLEFUELADJUSTMENT M A I N FUEL
TURNS OPEN-

~ ~~

Fig. 3-25 C-Series Carburetor Adjustment 3-8

C-I61 TWIN
ENGINE OIL Same as C-Series.
AIRFILTERSameas C-Seriesexcept:
saturate the precleaner in engine oil and
squeeze to remove excess oil.

WING N U T
SPEED

Fig. 3-30C-161Twin Carburetor

Adjustment
FINAL ADJUSTMENT
PLATE
1. Placegovernorspeed control lever i n
CARTRIDGE "IDLE" position.
Holdthrottle lever
against idle stop and set idle speed ad-
justing screw toobtain1450 R.P.M.
Turn idle valve slowly clockwise (lean
mixture) until enginemisses or R.P.M.
Fig. 3-28C-161TwinAirFilter slows. Then turn idle
valve
turn
counterclockwise.
BATTERYCHECKAs described on page
3-4. 2.Holdthrottleshaft in closedposition
and adjust idle speed screw to 900
TUNE-UP PROCEDURE R.P.M. Release the throttle. Withremote
control in idle position, adjust tab "A"
Spark Plugs Same as B-Series. to obtain to 1450 R.P.M. See Fig. 3-31.
Points and Condenser- The breaker points
on Briggs & Stratton engines are located be-
hind the flywheel.Refer to Briggs & Stratton
"Twin
Cylinder Service Instructions"
(Briggs & Stratton Part Number 271 172) for
correct service procedures.

POINT
GAP .020" ADJUSTMENT

CONNECTION
DECREASE TOOL
I
Fig. 3-31 C-161 Twin Governor Idle Spring
NOTE:Governed idle must be adjusted
on all engines for proper operation. The
smaller spring keeps the engine
on
Fig. 3-29 (C-161 Twin Breaker Points governor, even at idle speed. If moderate
loads are applied at idle, the engine w i l l
TIMING Same as C-Series. not stall. Idle speed should be no lower
than 1100 R.P.M.
CARBURETOR ADJUSTMENT Turn
needle valve clockwise until it just closes. 3. Placegovernorspeed control lever i n
VALVE MAY BE DAMAGEDBYTURNING fast position. Then turn needle valve i n
IT IN TOO FAR. Now open needle valve 1½ slowlyclockwise(lean)
until engine
turns counterclockwise. Close idle valve in missesor R.P.M. slows. Then turn
same manner and open1½ turns. This initial needle valve ½ turn counterclockwise.
adjustment w i l l permitthe engine to be If engine does not accelerate properly,
started and warmed up prior to final adjust- readjust needle valveapproximately 1/8
ment. See Fig. 3-30. turn counterclockwise (richer).

3-9
ENGINE SECTION 4
CHOKE AND THROTTLE CONTROL ROUTING
AND ADJUSTMENT
B-SER I ES
Choke cable is located on left side of dash panel and
parallels gas line to carburetor. See Fig. 4-1. Adjust
chokebylooseningcableretainerclamp a t carburetor
end. Set chokehandle infull COLD position. Then
tighten retainer clamp to hold choke butterfly in fully
closed position.
Throttle cable is located on right side of dashpanel
leading from control handle to governor. See Fig. 4-1.
Adjust throttle bylooseningcableretainerclamp at
engine. Set throttle handle to full OPERATE position.
Tightenretainerclamp toholdthrottleinfully open
position.

Fig. 4-2 C-81 Choke Linkage

Fig. 4-1 B-Series Choke and Throttle Linkage

C-SERIES
Fig. 4-3 C-81 Throttle Linkage
Chokecable is located on left side of dashpanel. It
passes around bottom of engine through two cable clips
and into a retainer clampa t carburetor. Adjust choke by C-SERI ES (Except C-81)
loosening cable retainer clamp a t carburetor. Set handle
Throttle cable is located on right side of dashpanel.
in full COLD position and tighten retainerclamp to
hold choke butterfly in fully closed position. See Fig.
It passes through a cable clip on right side of engine into
throttle control bracket. See Fig. 4-4. To adjust,place
4-2.
throttleinfull OPERATE position. Loosen throttle
setscrew and rotate throttle control bracket clockwiseto
C-81 (Only)
stop position. Tighten throttle cable setscrew.
Throttle cable is located on right side of dashpanel,
leadingunderengine into a retainerclamp.End of
throttle wire inserts into first holeabove stop pin. See D-SER I ES
Fig. 4-3. Adjust throttle bylooseningcableretainer D160
clamp. Set throttle handle to full OPERATE position.
Tighten retainer clamp with throttle in fully open posi- Chokecable is routed from control handle, around
tion and stop pin against bracket. battery, through retainer clip on engine to choke lever
oncarburetor. Adjust choke with chokehandle in the
COLD-START position. Loosen cable clamp on engine.
Tighten cable clamp to hold choke butterfly in closed
position. See Fig. 4-5.

4- 1
SECTION 4
Fig. 4-4 C-Series (Except C-81) Throttle Linkage
Fig. 4-5 D-160 Chokeand Throttle Linkage
Throttle linkage consists of a control rod attached to
throttle lever with a cotter pin. Forward end of rod is
attached to throttle governor bellcrank with ball swivel
bolt.
Adjust the throttle by placing throttle control lever
in FAST position. Adjust ballswivelstud so bellcrank
contacts rear step.
D200
Chokecable is routed from control handle through
cable clamp on top of engine to choke lever on carbure-
tor. Adjust choke same as D-160. See Fig. 4-6.
Throttle linkage consists of a control rod from
throttle lever attached to governor control bellcrank a t
secondhole from top. Adjust throttle same as D-160.
4-2
Fig. 4-6 D200 Choke and Throttle Linkage
ENGINE REMOVE AND REPLACE
I Forenginerepairoperations,refer to enginemanu-
facturer literature (Briggs and Stratton or Kohler) or
Wheel Horse Onan Engine Repair Manual.
B-SERI ES
1. Remove negative battery cable.
2. Disconnectchokeand throttle cables, fuel line,and
all four electric lines: magneto ground (green),
alternator/lights (yellow), alternator/charge (red),
starter (black).
3. Separate PTO linkage under frame by removing clevis
pin and hairpin cotter a t PTO clutch turnbuckle.
4.RemovePTObrake adjustment screwandbracket.
5. Remove PTO clutch cone assembly.
6. Remove crankshaft bolt and bearing race.
7. Relieve drive belt tension by depressing clutch pedal
andremove remaining PTO clutch housing from
crankshaft.
8. Remove four (4) engine mounting bolts and lift
engine off frame.
For engine installation, reverseremovalprocedure.
See Fig. 4-7.
Fig. 4-7 B-Series Engine and Clutch Removal
 SECTION 4

C-SERI ES 3. Disconnect electric wires to coil, starter, orange wire

1. Remove negative battery cable. to rectifier plug,headlights,andPTO clutch. Mark
2. Disconnectchokeand throttle cables, fuel lines,and wire colors for replacement.
all electric lines: 4. Removegrille.
5. Removeupper muffler clamps,and four (4) bolts on
red 2 wires to solenoid grille shroud.
battery cable to solenoid 6. Remove mufflers and complete hood and grille shroud
black coil assembly.
rectifier regulator plug 7. Remove four (4) bolts holding engine to frameand
orange rectifier plug
slide engine forward until the flex coupling slides off
3. Remove the belt guard. pump drive shaft.
4.Remove the hairpin cotter from the PTO clutch rod. 8. Remove the engine from the frame.
5. Remove the PTO shaft clevis pin, and pivot yoke away
from shaft. For installation, reverseremovalprocedure.
Take
6. Remove the PTO brake. special note when assembling the flex coupling. See Fig.
7. Disengage the transmission drive clutch on automatic 4-9 and special instructions in Section 1.
models or depress clutch on 8-speed models.
8.Removedrive belt from the transmission drive pulley
and slide belt forward to clear engine pulley.
9.Remove through bolts from front isomounts.
10. Remove nuts securing rear isomount block to frame.
11.Removeengine with rear block still attached. See
Fig.4-8.

For engine installation:

1. Align front isomount through bolt with front block,
but do not tighten.
2. Maneuverrear block so studs drop through holes in
frame and secure with nuts.
3. Tighten all mounting bolts.

Fig. 4-9 D-160/D-200 Flex Coupling

D-200
1. Remove negative battery cable.
2. Disconnect choke and throttle controls and fuel line
from fuel pump.
3. Disconnect electric wires to coil, starter, headlights,
andorange wire to rectifier plug.Mark wirecolors
REMOVE LONG THROUGH
for replacement.
BOLTS (2) FROM 4: Remove mufflers and complete hood and grille shroud
ISOMOUNTS assembly.
5. Disconnect the PTO rod trunnion from the clutch bar.
6. Remove four (4) bolts holding engine to frameand
slide engine forward until the flex coupling slides off
pump drive shaft.
7. Remove the engine from the frame.
For installation, reverseremoval
procedure.
Take
special note when assembling the flex coupling. See Fig.
4-9 and special instructions in Section 1

REAR BLOCK

Fig. 4-8 C-Series Engine Mounting

D-SERI ES
D-160
1.Removenegative battery cable.
2. Disconnect choke and throttle controls, and fuel line
from fuel pump.
4-3
C-161 TWIN ENGINEREMOVEANDREPLACE
1 . Remove negative battery cable.
CHOKE AND THROTTLE CONTROL 2. Disconnect chokeand throttle cables,
ROUTING AND ADJUSTMENT fuel lines, hood stop cable,and all
electric lines:
The choke control is located onthe left battery cable to solenoid
side of the dash panel. The choke cable runs black magneto ground
over the top of the engine and connects to
the rear of the carburetor. Set the handle in red & yellow alternator plug
the RUN position and tighten the retaining 3. Remove the belt guard.
clamp toholdthe choke butteryfly in the
f u l l open position. 4. Remove the hairpin cotter from the
PTO
clutch rod.
The throttle control is located on the right 5 . Remove the PTO shaft clevis pin, and
sideofthe dash panel. The throttle cable pivot yoke away from shaft.
runs over the top of theengine and connects
to the governor linkage at thetop of the 6. Remove the PTO brake.
engine. Set the throttle to the f u l l OPERATE 7 . Disengage thetransmission
drive
position and tighten the clamp to hold the clutch on automatic models or depress
throttle in the fully open position. clutch on 8-speed models.
8. Remove drive belt from the transmis-
sion drive pulleyand slide belt forward
to clear engine pulley.
9. Remove through bolts from front iso-
mounts.
10. Remove nuts securing rear isomount
block to frame.
11. Remove engine with rear block still
attached. See Fig. 4-8.

FOR ENGINE INSTALLATION:

1. Align front isomount through bolt with
front block, but do not tighten.
2. Maneuver rear block so studs drop
through holes in frame and secure with
nuts.
Fig. 4-10 C-I 61 Twin Chokeand
Throttle Controls 3. Tighten a l l mountingbolts.

4-4
CLUTCH, BRAKES, SECTION 5

'TRANSMISSION/TRANSAXLE
B-SERIES 8. Cut old belt orremove by working belt through gear
shift access hole.
Clutch 9. Feed half the new belt through gearshift access hole af
Transmission is disengaged from the engine by clutching endand halfaroundthegearshiftlever through the
the drive belt. access hole forward end.
10. Place forward end of belt over engine drive pulley, and re
place pulley onto engine shaft and secure with bolt and
race.
11. Place aft end of belt over transmission pulley.
12. Route belt around idler pulleys.
13. Replace belt guides and retaining nuts.
14. Release the clutch, check belt alignment,and set bel
guides as shown in Fig. 51.
15. ReplacePTOconeandlinkage,and adjust PTObrake
See Section 9.

Brakes
The B-Series employsa positive action disc type brake on
the transaxle. See Fig. 52.

Fig. 5-1 &Series Belt Routing and Linkage

idler Pulleys
Two idler pulleys are
used onthe
drive belt. A flat
pulley is locatedonthe idler lever,and a V pulley is
stationary. No adjustment can be made to either pulley.

Belt Guides
Both idler pulleys use wire type belt guides. The guides
can rotate around the pulleys and must be correctly adjust-
ed.
To adjustthe belt guides,loosen thenuts holding the
guides and move the guides to positions shown in Fig. 51.
Tighten nuts securely.
Two belt guides are used to capture belt a t engine pulley.
Theseguides should be adjusted to 1/16 inch (1.5 mm) Fig. 5-2 &Series Brake Adjustment
from drive belt with the clutch pedal released.
Brake Adjustment
Belt Replacement 1. Depress the foot brakeand set parkingbrake in the
1. Place gear shift lever in neutral. first notch. See Fig. 53.
2. SeparatePTOlinkageunderframe by removing clevis 2. Loosen lock nut and tighten adjusting nut on brake cam
pin and hairpin cotter a t PTO clutch turnbuckle. lever. See Fig. 52.
3. Remove PTO brake adjustment screw and bracket. 3. Push or pull tractor by hand. Proper brake adjustment is
4. Remove PTO clutch cone assembly. achieved when rear wheels skid across floor.
5. Remove crankshaft bolt and bearing race. 4. Release brakesandcheck that brakedisc turns freely.
6. Relieve drive belt tension by depressing clutch pedal and 5. Tighten the lock nut andrecheckbrake adjustment.
remove remaining PTO clutch housing from crankshaft.
7. Remove idler pulley belt guides.

I When removing belt guides, pulleys arefree

are not replaced.
if nuts
SECTION 5

Fig. 5-3 B-Series ParkingFig.

Lever
Brake 5-5 C-Series
8-Speed Belt Routing
Clutch Rod Adjustment - 8-Speed Models
Transaxle &speed The rod clutch adjustment is made to adjust
Forcompleterepairoperations,refer t o manufac- clutch pedal position. To reposition pedal, adjust
the
turer's service manual for Peerless Model 669. position of the threaded trunnion on the clutch rod, a t the
left rear of the vehicle. See Fig. 56. The adjustment is
moreeasilymade bydisconnectingthe clutch rod a t the
clutch pedal.
-
Belt Guide Adjustment 8-Speed Models
Belt guidetangsare located on the belt guard top and
bottom front edge. To adjust,bendtheguides with the
belt under tension.

Belt Replacement - 8-Speed Models

1. Remove belt guard and right side foot rest.
2. Loosen clutch idler pulley.
3. Depress clutch and slip belt off rear drive pulley.
4.RemovePTO rod trunnion.
5. Remove yoke clevis pin and pull yoke aside.
6.RemovePTObrake.
7. Remove old belt andreverseprocedure for new belt
installation. Adjust PTObrake. See Section 9.
Brake - 8-Speed Models
Fig. 5-4 B-Series Transaxle Thebrakeband, located onthe left side of thetrans-
mission,brakes thetransmission,and, in turn, brakes the
Remove and Replace Transaxle rearwheels. See Fig. 5-6.
1. Lift tractor to relieve weight from transaxle.
2. Place gearshift lever in neutral.
3. Depress clutch and slip drive belt off transaxle pulley.
4. Disconnect brake
leverand return spring a t brake.
5. Remove 3 bolts from transaxlesupportbracket.Fig.
54.
6.Remove 6 bolts from axle support brackets a t frame.
7. Raise tractor frame and remove transaxle while guiding
gearshift lever through access hole and the belt.
Reverse above procedure for replacement.

C-SERIES
Clutch - 8-Speed Models
Transmission is disengaged from the engine by clutching
the drive belt, located on the right side of vehicle. See Fig. BRAKE ADJUSTMENT *-r
a.
55. 6

52 Fig. 5 6 C-Series 8-Speed Clutch Pedal and Brake Adjustments

 SECTION 5

Brake Adjustment 8-Speed Models

1.
Depress the brakepedal
andengage parking brake.
2. With the parking brakeengaged,adjust the nut on the
end of the rod until the brake band is tight enough to
skid both rearwheels
when the tractor is pushed.
3. Tighten the nut another 1/2 turn.

When properly adjusted, the parking brake lever should

not travel to the end of the slot when parking brake is en-
gaged.

Transmission 8-Speed Models

Forcompleterepairoperations,refer to WheelHorse
Mechanical Transmission Repair Manual No. A-1392.

Fig. 5-8 C-Series 8-Speed Seat Pan Supports

Fig. 5-7 C-Series 8-Speed Transmission

Remove and Replace

Transmission
8-Speed
Models
1. Drain the transmission oil. Fig. 5-9 C-Series 8-Speed Transmission Removed
2. Remove gearshift and park brake knobs and shift cover
plate.
To replace transmission, reverse above procedure. Refill
3. Depress clutch pedal and slip belt off drive pulley.
with oil.
4. Remove seat hinge brackets andseat.
5. Unbolt seat pananddisconnect seat switch wiresand
Clutch Automatic Models
tail light wires if applicable.
6. Remove seat pan.
Transmission is disengaged from engine by clutching the
7. Remove two (2)bolts holding seat pan support bracket
drive belt located on the right side of vehicle. See Fig. 5-10.
to top of transmission.Remove fuel line and conduit
clamps,close fuel valve, anddisconnect fuel line a t Belt Guide Adjustment
tank.
Same procedure as 8-Speed.
I

I Secure fuel line to steering wheel to prevent fuel line

from draining. I Belt Replacement
Same procedure as 8-Speed, except that idler pulley
need not be loosened.
8. Remove two (2) bolts and nuts holding seat pan support
bracket (not the fuel tank forward bolts).
9. Lift off fuel tank along with both brackets, and set tank
aside.
IO. Drive spirol pin from range selector lever.
11. Remove clutch return spring from transmission casting.
12. Disconnect rear brake rod a t bellcrank.
13. Supportframe of tractor andremove four (4) bolts
holding transmission to frame. See Fig. 59.
14. Disconnectrangelever as transmission is pulled away
from frame. 53
 SECTION 5 I f the brake band is severely out of adjustment (too
tight), proper neutral adjustment will not be possible
due to restricted brakepedaltravel.Loosenbrake
bandadjustment nut completely, make theneutral
adjustment, then adjust the brake band.

Fig. 5-10 C-Series Automatic, Belt Routing

1 Brake/Motion Control Linkage - Automatic Models

Fig. 5-12 C-Series Automatic, Motion Control Neutral

Adjustment

Detent Alignment Adjustment

After neutral hasbeenadjusted,check to see if the
motion control lever is centered in the detent notch of the
detent spring. The spring incorporatesslotted bolt holes so
it may be adjusted as required to line up the neutral notch
with the control rod. See Fig. 5 1 1.

Motion Control Friction Adjustment

Thespeed control lever is friction-loaded t o hold any
selectedspeed in either direction. If the leverdoes not re-
mainwhere it is set during operation,adjust as follows:

Fig. 5-11 C-Series Automatic, Motion Control Linkage 1. Remove controls cover plate.
2. Release large locknut. See Fig. 5-11.
~ Motion Control Linkage Neutral Adjustment 3. Tighten friction collar to desired spring friction.
4. Tighten large locknut.

r-
Place the tractor on a level surface with engine running.
Depress the brake pedal and release. The tractor should not
creepand the rearwheels should be effectively locked.
If the tractor creeps on a level surface while in neutral,
adjust as follows:
1. Block the rear wheels off the ground.
2. Remove controls cover plate located in front of the seat.
3. Loosen the set screws in the arm with an allen wrench.
See Fig. 512.
The properamount offriction

1
is obtained when
approximately 6 Ibs. (1.4 N) of force a t the top of the
handle moves the control lever. The friction collar is
self-lubricatingand does not require added lubrication.

Brake Adjustment
4. Startthe engineand run a t full throttle. Engage the
drive clutch. Allow drive train to reach normal operating Thebrakeband, locatedonthe left side of thetrans-
temperature. mission,brakes thetransmissionand, in turn, brakes the
rear wheels. As the brake pedal is depressed, linkage returns
5. Depress the brake pedal fully and release.
6. Insert a short screwdriver through the hole in the nylon thetransmission to neutral, dynamically braking the trac-
tor. Thebrakeband is actuatedafterthetransmission
camand rotate theeccentric cam pin until therear
reachesneutral, providing additional braking action. The
wheels stop turning. This usually occurs a t a point mid-
brake band also serves as the parking brake.
waybetween forward andbackwardwheel rotation.
Toadjust the brake on C-Series automatic tractors,
t
follow the precedingprocedure outlined under "8-Speed
The lobe on the eccentric pin must be up for proper
Models." See Fig. 513.
adjustment.
A
7. Retighten the set screw in the arm and retest for neutral
a t full throttle. 5-4
 SECTION 5
Remove and Replace Transaxle
1. Drain the transaxle oil.
2. Remove knob from drive clutch handle and remove con-
trol cover plate.
3.Disengagetransmission drive clutch and slip belt off
drive pulley.
4. Remove seat hinge brackets and seat.
5. Unbolt seat pananddisconnect seat switch wiresand
tail light wires (if applicable).
6. Remove seat pan.
7. Remove two (2) bolts holding seat pan support bracket
to top of transaxle. Remove fuel line clamp and conduit
clamp (Ref. &Speed,Fig. 5-8).
8. Close fuel valve and disconnect gas line a t tank.

Secure fuel line to steering wheel to prevent fuel line

from draining.
Fig. 5-13 C-Series Automatic Brake Adjustment
9. Remove two (2) bolts and nuts holding seat pan support
bracket (Ref. &Speed, Fig. 5-8).
10. Lift off fuel tank along with both brackets and set tank
Remove and Replace Motion Control Linkage
aside.
11. Remove nut holding pin to rear of motion control lever
assembly. See Fig.5-14.
12.Remove left sidepanel.
13. Remove brake rod adjusting nut. (Ref. Fig. 5-13).
14.Models with hydraulic lift: disconnect two hydraulic
lines a t pump and mark for replacement (Ref. Fig. 5-8).
15. Supportframe of tractor andremove 4 bolts holding
transaxle to frame (Ref. &Speed,Fig. 5-9).
16. Remove transaxle assembly.
To replacetransaxle,reverseaboveprocedure. Refill
with oil. Adjust brakeband.

Remove and Replace Input Pulley

1. Remove right rear wheel.
2.Disengage drive clutch and slip belt off drive pulley.
3. Remove hex bolt on shaft and pull pulley.

Fig. 5-14 C-Series Motion Control Linkage Remove and Replace Pump/Motor
1. Completesteps 1 through 12 underTransaxleRemove
andReplace.
1. Remove controls cover plate and left side cover. 2.Remove left rear wheel for clearance.
2. Remove parking brake lever
assembly.
Remove nut 3. Complete steps 13 and 14 under Transaxle Remove and
holding pin to rear of motioncontrol leverassembly. Replace.
See Fig. 5-4. 4. Remove two transaxle case bolts holding top of drive
3.Remove bolt from motioncontrol shaft retaining tab. motor and two lower bolts holding bottom of drive
4. Release pressure on motioncontrol tension spring. motor to transaxle.
5. Pullshaft out farenough to expose woodruff key on 5. Remove pump and motor as an assembly.
left side of shaft.Removekey.
6. Pull shaft all the way out.
7. Carefully remove motion control handleassembly from always clean strainer and replace oil filter.
under gas line and electrical harness.

To replace pump/motor, reverse above procedure. Refill

Transmission/Transaxle Automatic Models with oil. Adjust brake band.
Forcompleterepairoperations,refer to WheelHorse
Automatic Transmission Repair Manual No. A-1391.

5-5
 SECTION 5
i Push Valve Function Implement Relief/Charge Valve
Because of the "dynamic brake" feature of the hydro- The implement relief valve is used to regulate hydraulic
static transmission, the tractor canbepushed for only a lift pressure. This valve limits pressure to maximum of 550
fewfeetbeforetherear wheels will lock. If the tractor to 700 psi (38 to 50 kg/cm²). It is located to the rear of
must be pushed, the manualbypassPushValvemustbe the pump housing. The charge pressure relief valve is loca-
opened. The valve is located inboard of the left rear wheel ted to the front of the pump housing on models equipped
on C-Series tractors. To operatethe valve. follow the in- with a hydraulic lift, and to the rear of the pump housing
structionsonthe "push valve" decal.The valve has a on models equipped with a manual lift. The charge pressure
square head and can be opened or closed with a wrench. Be relief valve limits pump and motor circuit hydraulic
sure to close the valve beforeoperating the tractor. pressure to 70 to 150 psi (4.9to 10.5 kg/cm²). See Fig.
5-17 and Fig. 5-18.

HYDROSTATIC PUMP END CAP

Fig. 5-15 C-Series Automatic, Push Valve

Handpush tractor only. Do not tow. Towing can

causeseveredamage to the hydrostatic transmission. Fig. 5-17 C-Series Automatic Charge Pressure Valve
(Manual Lift)
Acceleration Valves

Acceleration valves are used in the hydraulic drive circuit

to limitvehicle acceleration to a safe rate.
Two valves are used: a forward valve and a reverse valve.
See Fig. 516.

Although theacceleration valves look similar,they

are not alike.The forward valve, located a t the rear
of the end cap housing, incorporates wider relief flats
on the valve lands than does the reverse valve, located
a t the frontof theendcaphousing.The forward
valve may be used in place of the reverse valve; how-
ever,under no circumstance should the reverse valve
be substituted for the forward valve.

HYDROSTATICMOTOR END CAP

Fig. 5-18 C-Series Automatic Implement Relief/Charge
Valves and Hydraulic Hose Routing (Hydraulic Lift)

Hydraulic Hose and Line Routing

Hydraulic line routing is shown in Fig. 5 1 8.Connections
are shown in Fig. 5-19.

PLUG-
PLUG

BALL

Fig. 5-16 C-Series Automatic Acceleration Valves

I
 SECTION 5

An access hole is provided in the right console panel for

the neutral adjustment.
If the tractor creepswhen in neutral, adjust as follows:
1. Block the rear wheels off the ground.
FRONT OF 2. Loosenthecapscrew holding theeccentricassembly.
CYLINDER See Fig. 520.
3. Start the engineand run a t half throttle.Allow drive
train to reach normal operating temperature.
4. Depress the brake pedal and release.
5. Rotatetheeccentric until the rearwheelsstop. (This
usually occurs a t a point midway between forward and
backward wheel rotation.)
FRONT 6. Retightenthe capscrew while holding the eccentric
TRANSMISSION
assembly from turning.
(RETURN) 7. Increase engine speed to full throttle.
8. Move speed control lever in both directions and return it
to neutral with thepedal.(Repeatseveraltimesandre-
Fig. 5-19 C-Series Automatic Hydraulic Hose Connections adjust if necessary.)

Hydraulic Flushing Instructions

If the brake band is severely out of adjustment (too
To flush foreignmatter from lines,usekeroseneor
tight), proper neutral adjustment will not be possible
equivalent solvent.
due to restricted brakepedaltravel.Loosenbrake
To flush hydraulic lift valve, allow solvent toflow
band adjustment nut completely, make the neutral
through it.
adjustment, then adjust the brake band.
To flush pump and motor, it is necessary to disassemble
and overhaul.
To flush implement cylinder, blow all oil out by pushing Detent Alignment Adjustment
cylinder rod in and out. Flush with solvent. After motion control hasbeen adjusted for neutral, ad-
just the trunnion on the upper end of the control rod until
D-SERIES the control handle is in the neutral slot on the sidepanel.
Drive Line See Fig. 521.

The D-Series utilizes a flex coupling directly connecting Motion Control Friction Adjustment
the engine and the hydraulic pump. Oil is directed through
a hydraulic manifold connectingthepump to a hydraulic The motioncontrol lever is friction-loaded to hold a
motor. selectedspeed in either direction. If the leverdoes not re-
main where it is set during operation, the friction maybe
Brake/Motion Control Linkage increasedby tightening the
adjusting nut through the
access holelocated in the right panel. See Fig. 520.

The properamount offriction is obtained when

approximately 16 to 20 Ib. (3.6 to 4.5 N) of force a t
the handle moves the control lever.

Fig. 5-20 D-Series, Friction and Neutral Adjustment

Motion Control Linkage Neutral Adjustment

Place the tractor on a level surface with engine running.
Depress the brake pedal and release. The tractor should not
creepand the rearwheels should be effectively locked. Fig. 5-21 D-Series, Motion Control Detent Adjustment

5-7
SECTION 5
Brake Adjustment Parking Brake Adjustment
Thebrakeband, locatedonthe left side of thetrans-
mission,brakes thetransmissionand, in turn, brakes the
rearwheels.Asthebrakepedal is depressed,linkagere-
turns the transmission to neutral, dynamically braking the
tractor. Thebrakeband is actuated after the transmission
reaches neutral, providing additional braking action. The
brake band also serves as the parking brake.

Fig. 5-24 D-Series Park Brake Adjustment

1.Depressbrakepedaland pull up onparkbrake knob

locking it in the notch.
2. Adjust nutsonrear rod to hold brakepedal fully de-
pressed.
3.
Depressbrakepedal
and
move park
brake knob to
Fig. 5-22 D-Series, Brake Band Adjustment (front) bottom of slot,
making sure
brake
pedal
releases.

I f adjustment is too tight, the knob rod will not latch

in the slot.

Transaxle
Forcompleterepairoperations,refer to WheelHorse
Automatic Transmission Repair Manual No. A-1391.

Transaxle Removal
1. Drain the transaxle oil.
2. Block up the tractor with jackstandsadjacent to the
rear foot rest.
3.Remove both rear wheels.
ADJUSTMENT 4. Removeaxlehousing links,ordozerblade hitch if so
NUT
equipped.
5. Removebrake rod from brakeband (Ref. Fig. 5-23).
Fig. 5-23 D-Series, Brake Band Adjustment (rear)

Adjustment of the foot brake is as follows:

1. Release both foot and park brake.
2. Tighten thebandadjustment nut until the brakeband
can no longer be slid from side to side on the brake drum.
3. Back off the nut until the brakeband is againfree to
slide from side to side. See Fig.5-23.
4. Front brake adjustment is only required if the linkage is
removed.Thejam nuts areadjusted so thespacer just
contacts the spring, and the spring remains free to turn.
See Fig. 5-22.

5-8 Fig. 5-25 Transaxle

Assembly
 SECTION 5

6. Remove two 1/2 inch and two 3/8 inch cap screws that
retain the hydraulic manifold to the hydrostatic motor.
7. Tie up the rear of the manifold so it is held clear of the
motor pad.

Fig. 5-28 Lowering Transaxle

Fig. 5-26 Hydraulic Manifold

8. Remove dipstick and tube assembly from transaxle and

install a 1/2 inch pipe plug to keep out dirt.
9. Place a floor jack under transaxle assembly t o support it
for remaining bolt removal.
10. Remove four front butt plate-to-case bolts.
11. Remove four top frame plate to transaxle bolts.

Fig. 5-29 Transaxle Removed

Transaxle Installation
1. Install new seal rings on the motor manifold mounting
pad.The two large high pressure ports each require an
"0" ring with a square section backup ring centered on
top ofeach "0"ring.
2. Apply a small amount of grease in the recessesand on
Fig. 5-27 Transaxle Top Bolts
the rings to hold them in place.

12. Lower the transaxle, keeping it aligned between the butt

plate and the frame angles to prevent binding.
SECTION 5

Fig. 5-30 "0"Ring Installation Fig. 5-32 RaisingTransaxle

3. To keep out dirt during installation, cover the motor 5. Startthe top four case bolts using a punch for align-
manifold mounting padand seals with a piece of card-
ment. Leave them slightly loose a t this time.
board and hold with a piece of wire.

After transaxle installation, cut retaining wire and

removecardboard. Lift manifold to makesure seals
are still in place.

Fig. 5-33 Transaxle Top Bolts

6. Align the front case holes with the butt plate using a
punch.
7. Install the four front bolts and washers, making sure the
Fig. 5-31 Mounting PadCover
transaxle is squarely against both plates.
8. Tighten all eight bolts.
4. Place transaxle squarely in the jack, and jack the unit up
9. Install the axle links or hitch as applicable.
into place.Prevent binding between the front plate and
10. Connect the brake rod to the brake band.
the angle
brackets.
11. Install the dipstick and tube assembly.

5-10

10. Remove the pump and brackets.
Fig. 5-34 Transaxle Front Bolts
12. Carefully align and lower the manifold pad in placeand
install the two3/8 inch bolts and two1/2 inch bolts.
Make sure the special seal ring is used under the head
of the front 1/2 inch bolt.
13. Tighten all four bolts evenly and securely.
Fig. 5-35 Manifold Installation
14. Install both rearwheels.
15. Fill thetransaxle with oil, startthe engine,andcheck
for anyleaksand proper operation. Adjust brake band.
Pump Removal
To remove the hydrostatic pump, follow instructions in
section 4 for engine removal. The engine may be moved
forward on the frame for access to the pump, or remov-
ed from the frame, as desired.
Disconnect and remove the battery.
Removethe right consolepanel, together with the bat-
tery supports.
5-1 1
SECTION 5
4. Disconnect all three control rods connected to the pump
Iinkage.
5. Remove the four cap screws holding the front
manifold pad to the pump pad.The two rearscrews
have elastic stop nutson the top. An oil drain pan
should be placed under this area, since there will be some
oil loss.
6. Disconnect the hydraulic lift tubes located a t the top of
the pump.
7. Disconnect the temperature sending unit wire.
8. Remove the two 5/16 inch bolts and nuts that hold the
rear pump bracket to the steering gear support.
9. Remove the bolt that attaches the front pumpbracket
to the left side panel.
If a new pump is to be installed, carefully change the
brackets and linkage from the old pump to the new
Pump Installation
1. Place a small amount of cleangrease in the manifold
plate seal ring recesses and on the seal rings.
2. Place a small "0" ring in each of the low pressure port
recessesand a large "0" ring in each of the large high
pressure port recesses.
3. Place a square section type backup ring over the top of
each of the large "0" rings, centering them.
4. To facilitate alignment of the pump to the manifold pad,
fabricate two aligning pins.Cut the heads off two 3/8-
16 x 2 bolts to make two studs.Saw a screwdriver slot
and taper the ends as shown in Fig. 5-37.
Fig. 5-36 "0" Ring Ports
 SECTION 5

5.Screwthe aligning pins into the two front threaded

holes in thepump pad.
6. Install thepumpbyplacing it carefully in position.
7. Insert the aligning pins into the front manifold holes as
the pump is lowered into place.

Fig. 5-39 Manifold Installed

Fig. 5-37 Aligning Pins

8. Allow the pump bracket to reston thesteering gear

brace. install punches through the sidepanelholesand
into the front bracket to hold the pump in position.
9. Install the two 5/16 inch bolts and nuts andsecurethe
rear pump bracket to the steeringgear brace.
10.Secure the left panel to the front bracket with the bolt
and nut.
11.
Connect the hydraulic tubes to the pump fittings.
12. Connect thetemperature indicator wire to thesending
unit.

Fig. 5-40 Control Rod Connections

15. Connect the three control rods to their respective levers.

16. Install the right side panel and battery supports.

Fig. 5-38 Temperature Sending Unit

13. Install the two rear manifold-to-pump capscrews from

underneath. Place the 3/8 inch elastic stop nuts on top,
but do not tighten a t this time.
14. Remove the two aligning studs and install the two front
cap
screwsand tighten all four capscrewsevenly.
Fig. 5-41 SidePanel Installation
5-12
 SECTION 5
17. Lubricate the pump splineand
splined washer with Motor Installation
"moly" grease and slide the engine carefully to the rear.
18. Engage the pump spline with the pump coupling; center
the engine on the pump shaft.

Fig. 5-43 Motor Mounting Area

Fig. 5 4 3 shows the motor mounting area with the intake

Fig. 5-42 Pump Spline Engagement
19. Bolt the engine securely to the frame.
20. Connect engine controls as required.
21. Install and connect the battery.
22. Install the grille shroud and hood.
23, Test the unit for proper operation.
24. Check the oil level, filling as required.
t 4. Center a square section backup ring on top of each of
If neutral and tension adjustments were moved, they
will require readjustment.
screen pulled out. The two cap screw holes on each side of
thescreenand the two top cornerholesare for the four
bolts which retain the motor to the case.
1. Apply a small amount of grease to the motor manifold
padrecessesandthe "0" rings to hold them in place.
2. Install two small "0" rings in the two low pressure ports.
3. Install a third small "0" ring around the right front bolt
hole, located a t the top left corner of the manifold pad.
the large "0" rings and install them in the two large high
pressure ports.

When properly installed,the bottom of the backup

Motor Removal
rings will be just below the top of the recess. Be care-
1. Jack the tractor up under the frame and remove the left ful not toget dirt on the pad surface.
rear wheel.
2. Place an oil drain pan under the motor and transaxle to
catch oil as the motor is removed.
3.Remove the four cap screws that hold the manifold pad
to the motor (Ref. Fig. 546).
4. Tie up the manifold so it will clear the motor pad.
5. Disconnect brake rod from brake band.
6. Remove thenuts from the two bolts securing the top
section of the motor to thetransaxle (Ref. Fig. 544).
7.Remove the two lower motor-to-case capscrews which
thread into the case. (Ref. Fig. 5-43).
8. Remove the motor.

Fig. 5-44 "O"Ring Installation

5-13
SECTION 5
5. Install a new gasket on the transaxle.
6. Line the motor up on the two top case bolts and install
the nuts. Install the two lower cap screws.
4. Removethese "0" rings being careful to keep dirt away
from the open oil ports.
5. Remove the manifold by turning it past the steering gear
bracket and pulling it out towards rear of tractor.

Cover all open oil ports in both motor and pump to

keep loose dirt from entering.

Manifold Installation
Install new seal rings onthe manifold pad as follows:
1. Place a small amount of grease in the seal ring recesses
and on the seal rings.
2. Place a small "0" ring in each of the low pressure port
recesses and a large "0" ring in each of the high pressure
port recesses.
3.On top of eachlarge "0" ring, place a square section
type backupring.Center it exactly on top of each of
the "0" rings.

Fig. 5-45 Motor Installation

7. After the motor has been secured to the transaxle, check

the seal rings to make sure they are in position.
8. Release the back of the manifold if it was tied up during
the motor removal.
9. Line up the manifold and install the four (4) bolts. Make
sure the special seal washer is underthe head of the
right front bolt.
10. Connect brake rod to brake band.
11. Test the unit for proper operation.
12. Check the oil level, filling as required. Adjust the brake
band.

Fig. 5-47 "O"Ring Installation

4. Place a protective cardboard cover over the seal rings to
hold them in placeandkeep the areafree from dirt
during installation.

Fig. 5-46 Manifold Installed

Manifold Removal
1. Remove two 3/8 inch allen head screws and two 1/2 inch
capscrews holding the manifold pad to the motor.
2. Lift the manifold and remove the "0" rings.
3. Remove the two cap screws and two hex head bolts and
nuts holding the manifold to the pump. Fig. 5-48 Protected Seal Rings

5-14
 SECTION 5
Fig. 5-49 shows the location of the seal rings and mani-
fold attaching bolts a t the hydraulic motor pad.

Two 3/8 inch bolts andwashersareused a t the left

side of the pad,and two 1/2 inch bolts a t the right
side.Also note that the rear 1/2 inch bolt does not
use a washer.The front 1/2 inch bolt, however,re-
quires a special seal washer. An "0" ring is usedbe-
tweenthe manifold and the motor pad a t this loca-
tion.
These extra seals are required since this bolt goes
down into a pressure area. I f it is not sealed, there will
be a major oil leak.

Fig. 5-51 Rear Manifold Pad in Place

5. Carefully hold the manifold in place.

6. Align the bolt holes in therear manifold pad with the
bolt holes in the motor and install all four bolts.

front 1/2 inch bolt. Do not completely tighten the

7. Remove the protective cover from the front manifold

padandcheck to makesure all seal ringsare in place.
This is done by flexing thetubes down just enough to
feel if all the "0" ringsand backup ringsare in place.
Fig. 5-49 Ring and Bolt Locations
8. Positionthe manifold pad so the bolt holes line up.
9. Install the two short front hex screws.Leave them
Before installing the manifold, examine it carefully for
loose a t this time.
cracks around the tubing welds. Make sure the clamps pre-
vent the tubes from flexing. If the tubescanbemoved in 10. Install the two longerbolts in the two rearholes, with
a clamp,remove the clampsandshape them as required the elastic stop nuts on top.
11. Tighten all four boltsevenly, holding the nutson the
to hold the tubes firmly. Fig. 5-50 shows the front of the
rear bolts as required.
manifold as it is inserted past the steering gear bracket and
12. Tighten all four of the rear manifold pad-to-motor bolts.
turned to position it for attachment to the pump pad.
Leave the protective cover on this pad while the rear of the
manifold is being connected to the hydraulic motor.

Fig. 5-52 Front Manifold Pad Installed

Fig. 5-50 Positioning Front of Manifold
5-15
SECTION 5
Push Valve Function
Because of the “dynamic brake” feature of the hydro- HYDROSTATIC MOTOR END CAP
static transmission, the tractor can be pushed for only a few
feet before the rear wheels will lock. I f the tractor must be
pushed, the manualbypassPushValvemustbeopened.
The valve is located on theleft side of the tractor above the
footrest. To operate the valve, follow the instructions on
the ”push valve” decal.The valve has a squareheadand
can be opened or closed with a socketwrench.Besure to
close the valve before operating the tractor. See Fig. 5-53.

BALL

Fig. 5-54 Acceleration Valves

Implement Relief Valve

The implement relief valve is used to regulate hydraulic
lift pressure. This valve limits pressure to a maximum
of 550 to 700 psi (38to 50 kg/cm²). The valve is located
to the rear ofthe pump onthe right side. See Fig.5-55.
Thechargepressure relief valve is located on the left, and
limits pump and motor circuit hydraulic pressure to 70 to
150 psi (4.9 t o 10.5 kg/cm²).
Fig. 5-53 D-Series Push Valve

I Handpush tractor only. Do not tow. Towing can

causeseveredamage to the hydrostatic transmission.
I
Acceleration Valves
Acceleration valves are used in the hydraulic drive circuit
to limitvehicle acceleration to a safe rate.
Two valves are used: a forward valve and a reverse valve.
See Fig. 5-54.

Although the acceleration valves look similar, they are

not alike.The forward valve, located a t the rear of
the end cap housing, incorporates wider relief flats on
the valve lands than does the reverse valve, located a t
Fig. 5-55 D-Series Charge and Implement Relief Valves
the front of the end cap housing. The forward valve
may be used in place of the reverse valve; however,
undernocircumstancesshouldthereverse valve be
substituted for the forward valve.

5-16
 SECTION 5

Hydraulic Hose and Line Routing Fig. 5-56 D-Series Hydraulic Lines Routing
Routing of hydraulic lines is illustrated in Fig. 5-56.
Hydraulic Flushing Instructions
To flushforeignmatter from lines, use keroseneor
equivalentsolvent.
To flush hydraulic lift valve and manifold, allow solvent
to flow through it.
To flush pump and motor, it is necessary to dis-
assemble and
overhaul.
To flush implement cylinder, blow all oil out by pushing
cylinder rod in and out. Flush with solvent.

C-I61 TWIN

I Same as C-Series
I
Fig. 5-56 D-Series Hydraulic Lines Routing
 ELECTRICAL SYSTEM SECTION 6
B-SER I ES The alternator charging system normally requires no ser-
Ignition System vice other than periodically checkingthat all exposed wiring
and electrical connectionsonthe tractor areclean, tight,
Magneto ignition is used in the B-Series.The ignition
and in good condition.
switch is used to ground the magneto to stop the engine,
and to engage the starter.
Proper polarity is critical with an alternator equipped
The ignition switch continuity t e s t is performed as fol-
charging
system.
Alwaysdisconnect
the
battery
lows with the switch totally disconnected:
groundcable (negative) beforeworking on any part of
the electrical system. Verify all components are con-
Terminals Position
nected
correctly
beforereconnecting the
ground
OFF M & switch case cable (negative).
& RUN B
S START
& B
Interlock Switches
Continuity betweentheseterminals in thepositions
shown indicates a good switch. The B-Series interlock system incorporates two switches,
one operated by the foot pedal,andoneoperated by the
PTO clutch lever. I f the starter fails to operate, check the
Do not interchange B-Series with C and D-Series igni-
position of the switches in relation to their respective oper-
tion switches even though they look identical.
ating levers.Besure theswitches are actuatedwhenthe
PTO clutch lever is in the disengaged position, andwhen
Charging System
the foot pedal is depressed. Both interlock switchesmust
TheB-Series is equipped with a dual circuit alternator. be closed to start the engine.
One circuit provides 12 volts AC (alternatingcurrent) to
power the lights. The lights will NOT operate without the
engine running (lights optional on B-81).
Thesecond circuit providescharging current (12 volts
DC) to the battery.

Never interconnect the AC light circuit andthe DC

battery circuit as chargingsystem maybe seriously
damaged.

TheDC outputfor chargingthebattery is obtained

through use of a diode. If the battery does not recharge,
check the diode. The diode is contained in a fusecapsule
near the starter.

If the engine must be operated with the battery dis-

connected from thecharging system,
always
dis-
connecttheDC output lead a t the fusecapsule, to
avoid possible charging system damage.
Fig. 6-2 B-Series PTO Interlock Switch

Fig. 6-1 B-Series DC Output Diode and AC Output Lead Fig. 6-3 B-Series Foot Pedal Interlock Switch

6-1
SECTION 6
ThePTO interlock switch is located to the side of the
PTO lever. To removeorreplace this switch, first remove
the battery, turn the steering full left, disconnect the con-
nector, and remove the switch nut. See Fig.6-2.
The foot pedal interlock switch is located to the side of
the foot pedal. It is therefrigerator type andpresses out
from insidetheframe. See Fig.6-3.

Lighting Circuit
TheB-Seriesincorporatesan alternator (12V AC) sys-
tem for lighting only (lights optional on B-81).
A special spring clip washer is used on the hood axle rod
to assure hood electrical ground contact for the headlights.
See Fig. 6-4.

(PTO
BROWN

LIGHT
SWITCH
(OPTIONALON B-B1)

Fig. 6-6 B-Series Wiring Diagram

Fig. 6-4 B-Series Hood Spring Clip C-SERIES

Wiring Harness Ignition System
Harness routingfor the B-Series is shown in Fig.6-5. Battery and coil ignition is used in the C-Series.
Refer to B-Series electrical circuit diagram for connections The ignition switch continuity test is performed as fol-
when servicing or replacing the entire harness. See Fig. 6-6. lows with the switch totally disconnected:

Position Terminals
OFF no continuity
RUN
START
Continuity betweenthese terminals in thepositions
shown indicates a good switch.

I Do not interchange C andD-Series ignition switch

with B-Series even though they look identical.

Charging System
A 15 amp alternator system is used to supply electrical
power to charge the battery. Battery power then operates
coil ignition, cranking and electrical accessories. Regulation
is provided by solid state rectifier/regulator. This "senses"
the conditionof thebatteryandcontrolsand limits the
chargerate.Sinceheat is generated, cooling fins are pro-
vided on the rectifier/regulator. It should be kept uncover-

Fig. 6-5 &Series Wiring Harness

6-2
 SECTION 6

ed and clean to allow proper ventilation when the tractor is

in operation.The alternator chargingsystemrequiresno
service otherthan periodically checking that all exposed
wiring and electrical connections on the tractor areclean,
tight, and in good condition.
Disconnect the rectifier/regulator plug whencharging
the battery in the tractor or when using a booster battery
to start the engine. The rectifier/regulator is located behind
the engine, just below the battery.

Proper polarity is critical with an alternator equipped

charging
system.
Always
disconnect the battery
ground cable(negative)before working on any part
oftheelectrical system. Verify all components are
connected correctly before reconnecting the ground
cable (negative) or damage to alternator system com-
ponents will result.
Fig. 6-8 C-Series Automatic Foot Pedal Interlock Switch
Never run theengine if the battery is removed,or
if the battery is not connected to the charging system. The other safety switch is actuated by the PTO clutch
Serious damage to charging system components may lever. I f the starter fails to operate,check the position of
result. the switches in relation to their respective operating levers.
Be sure the switchesare activated when the PTO clutch
lever is in the disengaged position and when the foot pedal
Charging System Test is depressed.
Both interlock switchesmust be closed in order to
Theoverallchargesystem is testedbyplacing a DC start the engine.Check the switches by testing for contin-
voltmeter across the battery terminals with the engine run- uity. Check the PTO switch between the black wires, then
ning a t full throttle. Thereadingshould be 13.5 volts. across the red wires.

Ammeter Test Interlock Switch Locations and Replacement

To test ammeter, turn ignition switch on and turn lights
on. Ammeter should show discharge. If not equipped with
lights,start the tractor and note initial ammeterreading,
quickly dropping off to zero.
Interlock Switches
TheC-Seriessafety interlock system incorporates two
switches. One switch is actuated by the clutch pedal on 8-
speedmodelsandby the brake/return to neutral pedal on
automatic models. See Fig. 6-7 andFig.6-8.
The foot pedal switch in both the 8-speed and the auto-
matic models is located on the hood stand under the con-
trols access panel. To remove or replace this switch on
either model, remove the controls cover plate to expose the
switch and remove side panel to remove switch nut.
The PTO switch in all C-Series is located to the right rear
of the battery. To remove or replace this switch, disconnect
theelectricalconnector, remove the battery, remove the
large switch nut and pull switch out. See Fig. 6-9.

ACTUATING LEVER
PART OF CLUTCH
IDLER ARM,
OF THIS PANEL
:- \I

Fig. 6-7 C-Series Clutch Pedal Interlock Switch Fig. 6-9 C-Series PTO Interlock Switch

6-3
SECTION 6

Seat Switch
A seat switch is incorporated on C-Series tractors. If the
driver rises off his seat with the PTOengaged, the seat
switch interrupts the ignitioncoil voltageand the engine
stops.The seat switch has no effect onthe tractor unless
the PTO lever is engaged.
The engine can be started without the seat switch being
depressed.

Fig. 6-11a C-Series Harness Routing (All but C-81)

Fig. 6-10 C-Series Seat Switch

The seat switch is located under the seat in the seat pan.
See Fig. 6-10. To replace the switch, remove the transaxle
oil dip stick for finger access to theswitch. Remove the
nut from the top ofthe switch and pull the switch from the
seat pan.

Lighting Circuit
The light circuit on C-Series tractors (optional onsome
models) is powered by the battery. The lights operate Fig. 6-11b C-SeriesHarness Routing (C-81 Only)
when the ignition switch is in the Run position. A 20 amp
SFE fuse is part of the light circuit. The fuse is contained in
a fusecapsuleconnectedbetween the ignition switch and
the light switch, behind the dash panel.

Wiring Harness
Harness routing for the C-Series is shown in Fig. 6-1 l a
and Fig. 6-11 b. Refer to C-Series electrical circuit diagram
for connections when servicing or replacing the entire har-
ness. See Fig. 6-13.

Fig. 6-12 C-Series Harness Routing

 SECTION 6

I
I ON I

Fig. 6-13 C-Series Wiring Diagram

D-SERIES Charging System Test

Ignition System Same as C-Series.
TheD-Series utilizes battery and coil ignition. Refer to
C-Series for ignition switch testing procedure. Ammeter Test
Same as C-Series.
Charging System
Same as C-Series.
The rectifier/regulator is located Interlock Switches
behind the engine below the battery, on the inside of the TheD-Seriessafety interlock system incorporates two
left side panel. switches.
The two interlock switches
are
operated
6-5
SECTION 6
by the brake/return to neutral pedalandthePTO clutch D-200
control. If thestarterfails to operate,checkthe position The PTO interlock switch is located on the mechani-
ofthe switch in relation to its respective operating lever. cal PTOhandle bracket under the hood. To replace the
Thestarter willnot operate
unless both switchesare switch, remove the battery and engage the PTO for
closed.The D-160 electric PTO switch and the D-200 access to the switch nut. See Fig. 6-15.
mechanicalPTOlevermustbe in the off anddisengaged The D-200foot pedal switch location and replacement
positionsrespectively. Check the switches forcontinuity. is identical to the D-160.
ThePTO switch should have continuity betweenblack
wires and continuity between red wires. Seat Switch
A seat switch is incorporated ontheD-Series tractors.
I t s operation and purpose is same as C-Series.

Fig. 6-14 DSeries Foot Pedal Interlock Switch

Fig. 6-16 D-Series Seat Switch

To replace the seat switch, raisethe seat, removethe

switch nut, and pull switch from frame. See Fig.6-16.

Lighting Circuit
The light circuit onD-Series tractors is powered by the
12V battery. The lights operate when the ignition switch is
in the Run position. A 20 amp SFE fuse is part of the light
circuit. Thefuse is contained in a fusecapsuleconnected
between the ignition switch and the light switch, just below
the edge of the instrument panel. See Fig. 6-17.

Fig. 6-15 D-200 PTO I

nterlock Switch

Interlock Switch Locations and Replacement

D-160
The
PTO is interlocked through the PTO switch
onthe control panel. To replace,removedashpanel
and change switch.
The foot pedal interlock switch is located beneath
the solenoid by the right frame member. See Fig. 6-14.
To replace theswitch, removethelarge nut from the
switch, andrelease from the holding bracket,anddis-
connectwires.

Fig. 6-17 D-SeriesFuse Holder

6-6
 SECTION 6
Wiring Harness
Harness routing forthe D-Series is shown in Figures 6-18,
6-19,and6-20.Refer to the D-Seriesrespectivemodel
electrical circuit diagram for connections when servicing or
replacing
theentire harness.
SeeFig. 6-21
and6-22.

Fig. 6-18 D-Series Control Console Wiring (D-200Shown) Fig. 6-19 D-Series Headlightand PTO Wiring (D-160 Shown)

Fig. 6-20 D-Series Harness Routing

6-7
SECTION 6

HEAD LIGHTS

a
LIGHT
SWITCH

W
W

C
CONNECTOR
2-WIRE
CONNECTOR
YELLOW-

/SWITCH

HOUR METER

Fig. 6-21 D-160 Wiring Diagram

6-8
 HEADLIGHTS

SWITCH

SWITCH

TAIL LIGHTS
-YELLOW

I
I

Fig. 6-22 D-200 Wiring Diagram

6-9
 C-161 TWIN CHARGING SYSTEM TEST

IGNITION SYSTEM Theoverallchargingsystemistested by

placing a DC voltmeter across the battery ter-
TheC-161Twinusesmagnetoignition.A minals with the engine running at full throttle.
relayisusedtogroundthemagneto,which The reading should be at least 13.5 volts.
stops the engine. The ignition switch is used
AMMETER TEST
to supply voltage to the relay, and engage the
starter solenoid. To test ammeter, start the engine. Ammeter
should indicate discharge while the engine is
Theignitionswitchcontinuitytestisper- cranking. The ammeter reading will be around
formed as f o l l o w s w i t h t h e s w i t c h t o t a l l y d i s - zero at idle speed; a constant charge reading
connected: will be indicated at full engine RPM.
INTERLOCK SWITCHES
Terminals Position
Same as C-Series.
OFF no continuity
&I&A RUN SEAT SWITCH
B&S&I START
AseatswitchisincorporatedonC-Series
Continuity between these terminals in the tractors. If thedriverrisesoffhisseatwith
positions shown indicates a good switch. the PTO engaged, the seat switch interrupts the
relay coil voltage which grounds the magneto,
Do not interchange C and D-Series ignition causing the engine to stop. The seat switch has
switchwithB-Serieseventhoughthey no effect on the tractor unless the PTO lever
look identical. is engaged.
The engine can be started without the seat
CHARGING SYSTEM switch being depressed.

T h eC - 1 6 1T w i ni se q u i p p e dw i t had u a l The seat switch is located under the seat in

circuit alternator. One circuit provides 12 volts theseatpan. See Fig. 6-10 . Toreplacethe
AC(alternatingcurrent)topowerthelights. switch, remove the transaxle oil dip stick for
The lights will NOT operate without the engine fingeraccesstotheswitch.Removethe nut
running. from the top of the switch and pull the switch
f r o m t h e seat pan.
The second circuit provides charging current
LIGHTING CIRCUIT
(12 volts DC) to the battery.
The C-I 61 incorporates an alternator system
(12V A.C.) for lighting only. The lights work
only when the engine is running.
the DC battery circuit as charging system
WIRING HARNESS
Harness routing
for
the
C-161Twin
is
The alternator charging system requires no shown in Fig. 6-23. Refer t o C-Series electrical
serviceotherthanperiodicallycheckingthat circuit diagram for connections when servicing
allexposedwiringandelectricalconnections or replacing the entire harness. See Fig. 6-24.
on the tractor are clean, tight, and in good con-
dition.

Disconnectthealternatorwiresplugwhen
charging the battery in the tractor or when us-
ing a booster battery to start the engine. The
alternator wires plug is located on top of the
engine.

Properpolarityiscriticalwithanalter-
natorequippedchargingsystem.Always
disconnect the battery ground cable (nega-
tive)beforeworkingonanypartofthe
electricalsystem.Verifyallcomponents
are connected correctly before reconnect-
ing the ground cable (negative) or dam-
age to alternator system components will
result.

Never run the engine if the battery is re-

moved, or if the battery is not connected
tothechargingsystem.Seriousdamage
charging
to system
components
may
result.

6-1 0
 TO ENGINE
STARTER

Fig. 6-23 C-161 Twin Harness Routing

6-1 1
 HEAD LIGHTS

I I
I
I

OUTPUT

BLACK

Fig. 6-24 C-161 TwinWiring Diagram

6-12
ATTACHMENT LIFTS SECTION 7
B-SERIES
The B-Series incorporates no attachment lift mechanism.
Refer to themanualsupplied with each attachment for Attachment Linkage
mountinginstructions.
Transport lift accessory 8-6717 Rotary Mower Trunnion No. 20 in Hole "A" of
may be added for use with rotary mowers. and Mid Mount Bellcrank No. 19. Slip Pin "E"
Cultivator of Lift Bar No. 27 into attach-
C-SERIES ment linkage.

Attachment Mounting Locations Dozer Blade and Trunnion No. 20 in Hole "A" of
Grader Blade Bellcrank No. 19. Attach blade
linkage to Hole "F" of Lift Bar
No. 27. For additional blade
height, place trunnion No. 20
in Hole "B".

Snowthrower Attach Snowthrower Linkage to

Hole "C" of Bellcrank No. 19.
Tiller, Slot Hitch Attach Rear Lift Cable to Hole
and Clevis Hitch "D" of Bellcrank No. 19.

Mid Lift Trunnion Adjustment

Adjust trunnion No. 20, nut No. 23, and eyebolt No. 22
so rubberbumpersonmowerpress firmly on bottom of
footrests when lift is fully raised.

Rear Lift Trunnion andChain Adjustment

Rear Mount Attachments
The chain adjustment has two positions, operational and
transport. For operation, the implement clevis is placed in
the last linkof the lift chain.Fortransportation,the
second last link is usually used.
The rear lift trunnion, located under thegas tank, is used
to adjust optimum height of the rear lift chain for best use
of each implement used. This rear lift trunnion is a "fine"
adjustment that complements the chain adjustment.

Remove Lift Linkage

Refer to Fig. 7-1
during
the following procedure.
1.Remove belt guard.
2. Remove left side panel and footrest.
3. Remove two hairpin cotters No. 14 from lift shaft No. 9
or 1.
Fig. 7-1 C-Series Lift Linkage
4.Removeone hairpin cotter No. 21 from chain trunnion
No. 20.
The lift bellcrank, No. 19 in Fig. 7-1, is actuated by the 5. Disconnect Dial-A-Hite control rod No. 34.
lift lever No. 1, or on C-141, C-161 Automatic models by a 6.Remove circlip (large) No. 17 fromright side of lift
hydraulic cylinder. The lift linkage, on certain attachments, shaft No. 1 or 9. Remove paint from shaft.
connects directly to the bellcrank. Other attachments con- 7. Pull lift lever or shaft No. 9 from left side t o reveal key
nect their lift linkage to the lift bar No. 27.Use the follow- No. 18.
ing chartfor correct linkage locations: 8. Remove key No. 18.
9. Remove lift leveror shaft No. 9 and bellcrank No. 19.

7-1
SECTION 7

Remove Hydraulic Cylinder

Refer to Fig. 7-1 and Fig. 7-2 during the following pro-
cedure.

Fig. 7-2 C-Series Hydraulic Lift System

1. Remove left side panel and footrest.

2. Disconnect hydraulic cylinder fromlift shaft No. 9.
3. Disconnect hydraulic hoses from cylinder noting hose
locations.
4. Disconnect brake pedal from brake rod.
5. Remove collar from brake pedal shaft.
6. Slide brake pedal, spacer, washer, and cylinder off shaft. Fig. 7-3 C-Series Hydraulic Lift Components

Overhaul Hydraulic Cylinder Remove Hydraulic Valve

Refer to Fig. 7-3 during the following procedure.
1. Remove circlip No. 1 a t end of hydraulic cylinder.
2. Withdraw piston No. 2 and all seals.
3. Replace "0" rings, gaskets, and seals with parts supplied
in rebuild kit, shown as No. 3 in Fig. 7-3.
1.Remove left sidepanelexposing cylinder and four hy-
draulic hose connections. See Fig.7-2. Mark two rear
hoses for identification during reassembly.
2. Disconnect 4 hydraulic hoses, twofrom the cylinder
and two from thepump.
3. Disconnect battery negative terminal.
4.Removeammeter mounting paneland disconnect two
(2) connectors from ammeter. See Fig. 7-4.
5. Remove controls cover plate.

Fig. 7-4 C-Series Hydraulic Valve Removal

7-2
 SECTION 7

6. Remove two mounting bolts holding valve bracket to Overhaul Hydraulic Valve
hoodstand. See Fi g. 7-2. 1. Remove valve and hoses from tractor (see Remove
7.Remove the valve andhoseassembly, guiding the hoses Hydraulic Valve).
through the large grommet in the frame.

For proper hoseconnections, see Fig. 7-5. After re-

assembling, check transaxleoil level after running the engine
and operating the lift system for one (1) minute.

REAR OF
FRONT OF

TRANSMISSION

(PRESSURE)

TRANSMISSION
Fig. 7-7 C-Series Hydraulic Valve Overhaul
(RETURN)
2. Remove spool cap and 1 /8 inch allen bolt.
Fig. 7-5 C-Series Hydraulic Valve Hose Connections 3. Replace "O”ring and spring.

Remove Hydraulic Valve Handle

1. Remove left side panel. Whenreassembling valve, makesure Allen head bolt
2. Disconnect battery negative terminal. clears washer under spring.

Remove Hydraulic Hoses

The entire hydraulic valve must be removed to replace
any or all hoses. Follow procedure for Remove Hydraulic
Valve.

D-SERIES, Automatic
Attachments Mounting Locations
The lift bellcrank No. 1 in Fig. 7-8 is actuated by the
hydraulic lift cylinder.
Foreach attachment, a specifichole in the lift bell-
crank is used for mounting attachments.The following
Fig. 7-6 C-Series Hydraulic Valve chart depicts the lift bellcrank hole to be used for a specific
attachment.
3. Removeammeter mounting paneland disconnect two
(2) connections from ammeter.
4. Remove controls cover plate.
5. Remove two mounting bolts holding valve bracket t o
frame. See Fig.7-2.
6. Tilt valve for access to push nut and pin.
7.Replacehandleandreassembleusingnewpush nut.

7-3
SECTION 7

Fig. 7-9 D-Series Hydraulic Hose Routing

3. Remove cotter pin and clevis pin from cylinder rod

separating bellcrank from cylinder.
4. Removesnap ring from left side of rear pivot pin and
slide pin to the right.
I 5. Remove hydraulic cylinder.
Fig. 7-8 D-Series Lift Linkage

After reassembling, check transaxleoil level after running

Attachment the engine and operating the lift system for one (1) minute.

Snow Thrower
Mower
Grader Blade Remove Hydraulic Valve
Dozer Blade
Float Lockout Pin
(Grader Blade)

To lock out the float feature, insert the 1/2 x 2 clevis

pin supplied with the graderblade through the two
holes of the lift armsand the hole in the float arm.
Secure the pin with the large hairpin cotter. Never
use themowerorsnowthrower with pin installed.

Remove Hydraulic Lift Mechanism

Refer to Fig. 7-8 during the following procedure.
1. Remove access cover plate in front of seat.
2. Remove cotter pin and clevis pin from cylinder rod.
3. Remove four (4) bolts from bellcrank pivot bearings.
4. Lower bellcrank assembly through bottom of frame.

Remove Hydraulic Cylinder

1. Remove access cover plate in front ofseat.
2. Disconnecthoses from front andrear of cylinder. Note
connections for reinstallation. See Fig. 7-9.

Fig. 7-10 D-Series Hydraulic System

 SECTION 7

1. Disconnect and remove battery. Overhaul Hydraulic Valve

2. Remove left side access plate. Same procedure as C-Series.
3. Disconnect two hoses and four metal tubular lines from
valve assembly. Note connections for reinstallation. Remove Hydraulic Hoses
4. Remove park brake knob, spring, and washer.
1. Remove battery.
5. Remove two bolts a t right side of parking brakeguide
2. Remove left side access plate,and access cover plate
plate,andremoveplate with hydraulic valve attached.
located over hydraulic cylinder.
6.
Remove three bolts securing valve body to parking
3. Removehoses a t cylinder and valve assembly. See f i g .
brake guide plate.
7-9.
After reassembling, check transaxle oil level after running After reassembling, check transaxleoil level after running
the engine and operating the lift system for one (1) minute. the engine and operating the lift system for one (1) minute.

Remove Hydraulic Valve Handle

1. Disconnect battery ground cable.
2. Remove switch nut from light switch. OnD-160,also
C-161 TWIN
remove switch nut from PTO switch.
Same as C-Series
3. Remove top and two outside screws from lower instru-
ment panel. Swing panel out of the way.
4. Remove nut and clevis pin from valve handle.
5. Slide handle off "S" link.
6.Replacehandleusingnewpush nut supplied with new
handle.
NOTES

7-5
CHASSIS SECTION &
B and C-SERIES
Steering Shaft Adjustments
Both B and C-Series use similar linkage.

Upper Adjustment
1. Release the set screw on the collar.
2. Press down on the steering wheel.
UPPER STEERING

LOWERSTEERINGSHAFT-

Fig. 8-1 B and C-Series Upper Steering Adjustment

3. Slidecollar up againstbushingand tighten set screw.

\
Lower Adjustment
Gear mesh is adjusted as follows:
1. Remove cotter pin from lower steering shaft. Fig. 8-3 B-Series Steering

I
!

UPPERSTEERINGSHAFT

Fig. 8-2 B and C-Series Lower Steering Adjustment

2. Add or remove enough shims so that 0 to .015 inch (.4

mm) end play remains in shaft.

8-1
Fig. 8-4 C-Series Steering
SECTION 8
D-SERIES
Wheel Alignment Adjustment 5. Removesteeringwheel from upper shaft and reposition
the wheel spokes and insert if necessary.
Toe-in amountshould be 1/16 to 1/8 inch with the
wheels straight ahead.
Turn steering wheel full right and then full left. Steering Remove SteeringGear
armswelded to the spindles should stop anequaldistance 1. Remove steering wheel and foam dust cover.
from their respective stops. I f adjustment is necessary, pro- 2. Disconnectthe
drag linkfrom steering gear
lever.
ceed as follows: 3. Cutany wire ties holding electrical wiring to steering
column.
1. Adjust the tie rods to obtain correct amount of toe-in.
2. Set steering gear on center by counting exact number of 4. Remove through bolts holding gear housing to steering
turns of the steering wheel, from full left t o full right. gear bracket. See Fig. 8-6.
3. Set wheel a t center of travel. 5. Remove steering gear assembly from the bottom.
4. Equalizethesteeringarm to axle stop clearance by
adjustingthelengthofthesteering drag link. Wheels
should now be pointing straight ahead.

Fig. 8-6 Steering Gear Bracket

Install Steering Gear

Steering gear is installed from the bottom.
1. Line up steering post and jacket.
2. Pushsteering
gear up through thegrommet in the
console.
3. Insert the two lever shaft nuts through the large hole in
the bracket.
4. Align and install the three bracket to steering gear bolts.
5. Center thejacket in the consolegrommetand tighten
the three bolts evenly.
Fig. 8-5 DSeries Steering
6. Connect the draglink tothe steering arm.
7. Install thesteeringwheelonthesplineduppershaft.
8. Check steering alignment by performing steps 2 through
4 under Wheel Alignment Adjustment.
 SECTION 8
Overhaul Steering Gear Disassembly
1. Place the steering gear assembly in a vise.
2. Back off the locknut and loosen the lever stud adjusting
screw.

Fig. 8-9 Adjusting Plug

Thedisassembledsteeringgear is shown in Fig. 8-10.

Fig. 8-7 Steering Gear Lever

3. Remove both large nuts andwasherandremove the
lever and shaft assembly.

GAUGE WASHER
USED FOR
ASSEMBLY ONLY

Fig. 8-10 Steering Gear Disassembled

Overhaul Steering Gear Assembly

1. Place the main housing firmly in a vise.
2. Lubricate andplace theupperandlower ball bearings
Fig. 8-8 Lever and Shaft and races on the worm shaft.
3. Insert the worm and bearings into the housing.
4. Remove the cotter pin and adjusting plug from the end
of the steeringgear housing.
5. Remove the steering post, worm, and bearings from the
housing.
 SECTION 8

GAUGE WASHER
USED FOR
ASSEMBLY ONLY

Fig. 8-11 Steering Gear Housing Fig. 8-13 LeverGauge Adjustment

4. Install the spring washer in the adjusting plug and thread 12. Tighten the lock nut against the inside nut andremove
the plug into the housing.
the 3/32 inch gaugewasher.
5. While turning the postandworm,screw the adjusting 13. Turn thesteeringshaft fromfullleft to full right.
plug in place until all end play is removed.
14. Use a screwdriver to tighten the lever stud until the high
spot (slight drag) is just felt as you pass through the
center of travel.

Fig. 8-12 Adjusting Plug installed

6. Tighten until a slight drag is felt while turning the steer-
ing shaft.
7. Install the cotter pin to lock the adjusting plug in place.
If the cotter pin does not line up witha slot after plug
adjustment, back out plug to align nearest slot.
Fig. 8-14 Adjusting Lever Stud
15 Hold the stud and tighten the locknut securely.Check
for proper operation andmakesure the adjustment did
not move when locking the nut.
16. Check steering alignment by performing steps 2 through
4 under Wheel Alignment Adjustment.

8. Back off the lever adjustingstud and insertthelever

shaft into the housing assembly. Lever stud adjustment maybemade in the tractor
9. Install the washerand two nuts but do not tighten. using a stubby screwdriver. Make sure to disconnect
the drag link, isolating the gear from thelinkage.
10. Install 3/32 inch thick washer as a gauge betweenthe
lever and housing as shown.
11. Tighten the inside nut until the lever is just against the
gaugewasher.
C-I61 TWIN
Same as C-Series.
POWER TAKE - OFF(PTO) SECTION 9
9-SERIES
PTO Clutch/Brake Adjustment
ThePTO clutch andbrakemay require periodic adjust-
ment due to normal wear of friction surfaces.
1. EngagePTO clutch.
2. Loosen the locknut on the PTO brake adjustment screw.
3. Turn the adjustment screw so there is a .010” (.25 mm)
gapbetween the brake pad and the clutch pulley face.
4. Tighten the locknut securely.
5. Check that the gap between the washer on the PTO rod
and the clutch/brake bracket is 1/4 inch (6.4 mm).
6. If clutch adjustment is necessary,change the length of
the PTO rod using the turnbuckle ontherod. Loosen
the locknut behind turnbuckle andremove the hairpin
cotter and clevis pin from the opposite end of the turn-
buckle.

Fig. 9-2 &Series PTO Clutch Removal

I It maybenecessary to readjust the PTObrake after

this adjustment is made.
I 5. Relieve drive belt tension by depressing clutch pedal and
remove PTO clutch housing from drive shaft.

Reverse above procedure for installation of PTO clutch.

C-SER IES
PTO Clutch Adjustment
Adjustment is required only when the PTO clutch slips
noticeably. If clutch slippage is apparent, turn the trunnion
toward the rear of the rod in one-turn intervals until clutch
slippage is eliminated.

Fig. 9-1 B-Series PTO Adjustments

Remove PTO Clutch

1. Separate PTO linkage under frame by removingclevis pin
and hairpin cotter a t PTO clutch turnbuckle.
2.
RemovePTObrake adjustment screw and
bracket.
3. Remove PTO clutch cone assembly.
4. Remove crankshaft bolt and bearing race.

Fig. 9-3 C-Series PTO Adjustments

PTO Brake Adjustment

1. Engage the PTO clutch.
2. Loosen the two bolts that hold the brake pad bracketto
the support bracket.
3. Place a .012 inch (.3 mm) feeler gauge between the brake
pad and the clutch pulley.
4. While holding the brake pad against the feeler gauge and
pulley, tighten the two brake bracket bolts.
9-1
SECTION 9
Remove PTO Clutch PTO Clutch Adjustment (D-200)
1. DisconnectPTO clutchrod and spring a t trunnion. To adjust the PTO clutch:
2. Remove yoke pin and swing yoke aside.
3. RemovePTObrake. 1. Remove the grille and disengage the PTO clutch.
4. Slide PTO hub off shaft. 2. Loosen the two brake bracket bolts.
5. Remove 4 bolts holding locking plates onto clutch plate 3. Loosen the lock nuts and adjust the turnbuckle on the
and face. clutchrod so that therear clutch platefacingjust
6. Slide bearing race off shaft. clears the pulley, allowing it to be turned freely by hand.
7. Remove clutch plate and facing. 4. EngagePTO clutch andchecktension.Thewasher at
the front end of the clutch rod should just clear the
Reverse above procedure for installation of PTO clutch. trunnion so it can be turned by hand.
5. Adjust PTO brake.

D-SERIES
PTO Clutch Adjustment (D-160)
The electric PTO clutch on the D-160 is self-
compensating for wearanddoes not requireadjustment.
If clutch problems are encountered, check the stator, PTO
switch and wiring for continuity. Replacethe rotor if the
clutch friction surface is excessively worn.

PTO Brake Adjustment (D-160)

To adjust the PTO brake:
1.Remove the grille.
2. Position a piece of .012 inch (.3mm) shim stock in each
of the four slots in the brake flange.
3. Turn ignition switch to Run position and PTO switch to
On position. Fig. 9-5 D-200 PTO Clutch Adjustment
4. Tilt the tractor's seat forward and place a weight on the
seat switch button, sufficient to actuate it.
5. Loosen the four locknuts holding thebrakeflange.
PTO Brake Adjustment (D-200)
6. Push onthe brakeflange until it bottoms out andre- To adjust PTO brake:
tighten the four locknuts. Do not over-tighten. 1. Remove the grille and engage the PTO clutch.
7. Turn PTO switch to Off position andremove ignition 2. Loosen the two brake bracket bolts.
key. 3. Place a .012 inch (.3mm) feeler gauge between the brake
8. Recheck the gap a t all four positions with a feeler gauge. pad and the clutch pulley.
The gap should be between .010 and .015 inches (.3 and 4. While holding the brakepadagainst the feelergauge
.4 mm). and pulley, tighten the two brake bracket bolts.

Fig. 9-4 D-160 PTO Adjustment Fig. 9-6 D-200 PTO Brake Adjustment

9-2
Remove PTO Clutch/Brake (D-160)
SECTION 9
1. Disconnect the PTO wire connector plug No. 9.
2.
Remove four nuts No. 14 holding clutch housing to
engine block.
3.Remove bolt No. 6, lockwasher No. 8,andlargespecial
washer No. 7 from center of shaft.
4. Slide clutch off crankshaft andremovesprings No. 15.
5. Remove four machinescrews No. 3, remove stator No.
2, andspacer No. 5.
To replacePTO clutch, reverseaboveprocedureand
adjustPTObrake.

Fig. 9-9 D-200 PTO Clutch/Brake

Clutch Removal
1. Disconnect the clutch rod trunnion from the clutch bars.
2.Loosen the two brake bracket bolts, allowing the brake
padand bracket to hang down to clear the pulley.

Fig. 9-7 D-160 Electric PTO Clutch

Fig. 9-10 D-200 Clutch Pulley Brake

3. Remove the clutch capscrewandspecialcapwasher.

4. Remove the front plate and pulley assembly from the
crankshaft.
5. Remove the 3/8 inch bolt and nut holding the clutch
barstogether.

Fig. 9-8 D-160 Electric PTO Clutch

PTO Clutch/Maintenance (D-200)

After each 100 hours of operation oroneyear, which-
evercomes first, the PTO clutch on the D-200 should be
cleanedand relubricated. Thismaintenance is covered as
part of Clutch Disassemblyand
Reassembly, following.

9-3
SECTION 9 Clutch Disassembly (D-200)
1. Press the pulley against the front clutch plate to com-
press the spring washers.
2. Remove the Spiroloc retaining ring.

Fig. 9-11 D-200 Clutch Removal

6. Remove the cotter pin and washer from the pivot hook.
7. Remove the two clutch bars from the hook and the
clutch collar. D-200 Fig. 9-14 Retaining Ring Removal

3. Lift the pulley off the front clutch hub.

4. Remove the one plain washerand the four spring wash-
ers. Note the position of eachwasher as it is removed.

RETAINING

Fig. 9-12 D-200 Clutch Removal

8. Slidethe clutch plate andthe clutch collar off the

PLATE & FACINGS WASHER
PLAIN
crankshaft.
Fig. 9 1 5 D-200 Clutch Plate and Washers

Clutch Reassembly (D-200)

1. Clean the front clutch hub.
2. Apply a thin coat of "moly" grease on the hub where
the washers and bearings go.
3. Install thespring washers as follows: the first washer
cuppedup, the secondwasher with the outer edges
down. Then the third washer, like the first, has the outer
edgesup. Finally, the fourth washer with outer edges
uP.

Fig. 9-13 D-200 Clutch Removal

 SECTION 9

8. Makesure of thealignment of the two barsand then

tighten the bolt and nut.
9. Place the spacer washer inside the front hub next to the
internal snapring.Thisdetermines the position of the
hub on the crankshaft.
10. Line up the keyway of the front clutch plate with the
crankshaft key.
11. Slide the plate and pulley assembly in position onthe
crankshaft.
12. Install the retaining bolt, washer, and end cap and tighten
securely.

Fig. 9-16 D200 Installing Retaining Ring

4. After the four cup washersare installed, place the plain

washer on top ofthem.
5. Place the pulley andbearingassemblyover the front
clutch hub with the notched section of the pulley up.
6. Press the pulley against the spring washers and install the
Spiroloc retaining ring.

Clutch Installation (D-200)

1. Checkand adjust PTO clutch hook so that the hook
centerline is 1 13/16 inch (4.6 cm) from the engine face.
2. Clean the crankshaft and key.
3. Apply a small amount of "moly" grease on the crank-
Fig. 9-18 D200 Installing PTO Clutch
shaft and key.
4. Line up the keyway in the rear clutch plate with the key 13. Line up the clutch rod trunnion and clutch bars.
and slide the clutch plate and collar assembly onto the 14. Attach the trunnion to the clutch barsand insertthe
crankshaft. washer and cotter pin to retain it.
5. Position the bottom end of the two clutch bars over the
pivot hook and over their respective clutch collar guide
pins.

Fig. 9-19 D200 PTO Clutch Rod

15. Operate the clutchcontrol leverandcheck the rear

Fig. 9-17 D-200 Installing Clutch Bar clutch plate and clutch bars for possibleinterference.
16. Adjust the clutch pivot hook in or out to eliminate any
6. Install the 3/8" bolt and nut to hold the clutch bars to- interference.
gether.
7. Before tightening the bolt, install the clutch hook wash-
er and cotter pin.

9-5
SECTION 9

C-I61 TWIN
PTO Adjustment Same as C-Series

PTO Brake Adjustment Same as C-Series

Remove PTO Clutch Sameas C-Series

PTO Thrust Bearing

Fig. 9-20 D200 PTO Clutch Assembled
17. Adjust PTO clutch and brake.
The C-161 Twin is equipped with a thrust
bearing between the engine and thedrive
pulley. Thebearing must be preloaded, if
the drive pulley is
ever loosened or removed.
To preloadthe thrust bearing,assemble
the PTO as described, and engage the PTO.
Tighten the setscrews i n the drive pulley
and disengage PTO.

NOTES